Aerosol delivery device

ABSTRACT

An aerosol delivery device comprises: a flow passage configured to provide fluid communication between a vaporizer and a mouthpiece aperture, so that the mouthpiece aperture receives a flow comprising an aerosol vapor formed from liquid vaporized by the vaporizer in use; and a turbulence inducing element, the turbulence inducing element located in the flow passage and configured to turn the flow towards a circumferential direction of the aerosol delivery device.

CROSS REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY REFERENCE STATEMENT

This application is a non-provisional application claiming benefit to the international application no. PCT/EP2020/56071 filed on Mar. 6, 2020, which claims priority to EP 19166315.2 filed on Mar. 29, 2019 and to EP 19166318.6 filed on Mar. 29, 2019. This application also claims benefit to the international application no. PCT/EP2020/56078 filed on Mar. 6, 2020, which claims priority to EP 19166271.7 filed on Mar. 29, 2019. This application also claims benefit to the international application no. PCT/EP2020/56081 filed on Mar. 6, 2020, which claims priority to EP 19166276.6 filed on Mar. 29, 2019. This application also claims benefit to the international application no. PCT/EP2020/56085 filed on Mar. 6, 2020, which claims priority to EP 19166284.0 filed on Mar. 29, 2019. This application also claims benefit to the international application no. PCT/EP2020/56095 filed on Mar. 6, 2020, which claims priority to EP 19166304.6 filed on Mar. 29, 2019. This application also claims benefit to the international application no. PCT/EP2020/56098 filed on Mar. 6, 2020, which claims priority to EP 19166313.7 filed on Mar. 29, 2019. The entire contents of each of the above referenced applications are hereby incorporated herein by reference in their entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to an aerosol delivery device, and, more particularly but not exclusively, to an aerosol delivery device in which a turbulence inducing element is configured to turn flow towards a circumferential direction.

The present disclosure also relates to an aerosol delivery device, and, more particularly but not exclusively, to an aerosol delivery device for a smoking substitute system.

The present disclosure also relates to an aerosol delivery device, and, more particularly but not exclusively, to an aerosol delivery device having an air-flow directing member in an airflow path.

The present disclosure also relates to a smoking substitute device and a system including the device, and, more particularly but not exclusively, to a smoking substitute device for delivering an aerosol to a user.

BACKGROUND

The smoking of tobacco is generally considered to expose a smoker to potentially harmful substances. It is generally thought that a significant amount of the potentially harmful substances is generated through the heat caused by the burning and/or combustion of the tobacco and the constituents of the burnt tobacco in the tobacco smoke itself.

Combustion of organic material such as tobacco is known to produce tar and other potentially harmful by-products. There have been proposed various smoking substitute devices in order to avoid the smoking of tobacco.

Such smoking substitute devices can form part of nicotine replacement therapies aimed at people who wish to stop smoking and overcome a dependence on nicotine.

Smoking substitute devices, which may also be known as electronic nicotine delivery systems, may comprise electronic systems that permit a user to simulate the act of smoking by producing an aerosol, also referred to as a “vapor”, which is drawn into the lungs through the mouth (inhaled) and then exhaled. The inhaled aerosol typically bears nicotine and/or flavorings without, or with fewer of, the odor and health risks associated with traditional smoking.

In general, smoking substitute devices are intended to provide a substitute for the rituals of smoking, whilst providing the user with a similar experience and satisfaction to those experienced with traditional smoking and tobacco products.

The popularity and use of smoking substitute devices has grown rapidly in the past few years. Some smoking substitute devices are designed to resemble a traditional cigarette and are cylindrical in form with a mouthpiece at one end. Other smoking substitute devices do not generally resemble a cigarette (for example, the smoking substitute device may have a generally box-like form).

There are a number of different categories of smoking substitute devices, each utilizing a different smoking substitute approach. A smoking substitute approach corresponds to the manner in which the substitute system operates for a user.

One approach for a smoking substitute device is the so-called “vaping” approach, in which a vaporizable liquid, typically referred to (and referred to herein) as “e-liquid”, is heated by a heating device to produce an aerosol vapor which is inhaled by a user. An e-liquid typically includes a base liquid as well as nicotine and/or flavorings. The resulting vapor therefore typically contains nicotine and/or flavorings. The base liquid may include propylene glycol and/or vegetable glycerin.

A typical vaping smoking substitute device includes a mouthpiece, a power source (typically a battery), a tank or liquid reservoir for containing e-liquid, as well as a heating device. In use, electrical energy is supplied from the power source to the heating device, which heats the e-liquid to produce an aerosol (or “vapor”) which is inhaled by a user through the mouthpiece.

Vaping smoking substitute devices can be configured in a variety of ways. For example, there are “closed system” vaping smoking substitute devices which typically have a heater and a sealed tank and heating element which is pre-filled with e liquid and is not intended to be refilled by an end user. One subset of closed system vaping smoking substitute devices include a main body which includes the power source, wherein the main body is configured to be physically and electrically coupled to a consumable including the tank and the heating element. In this way, when the tank of a consumable has been emptied, that consumable is disposed of. The main body can be reused by connecting it to a new, replacement, consumable. Another subset of closed system vaping smoking substitute devices are completely disposable, and intended for one-use only.

There are also “open system” vaping smoking substitute devices which typically have a tank that is configured to be refilled by a user, so the device can be used multiple times.

An example vaping smoking substitute device is the myblu™ e-cigarette. The myblu™ e cigarette is a closed system device which includes a main body and a consumable. The main body and consumable are physically and electrically coupled together by pushing the consumable into the main body. The main body includes a rechargeable battery. The consumable includes a mouthpiece, a sealed tank which contains e-liquid, as well as a vaporizer, which for this device is a heating filament coiled around a portion of a wick. The wick is partially immersed in the e-liquid and conveys e-liquid from the tank to the heating filament. The device is activated when a microprocessor on board the main body detects a user inhaling through the mouthpiece. When the device is activated, electrical energy is supplied from the power source to the vaporizer, which heats e-liquid from the tank to produce a vapor which is inhaled by a user through the mouthpiece.

Another example vaping smoking substitute device is the blu PROT™ e-cigarette. The blu PROT™ e cigarette is an open system device which includes a main body, a (refillable) tank, and a mouthpiece. The main body and tank are physically and electrically coupled together by screwing one to the other. The mouthpiece and refillable tank are physically coupled together by screwing one into the other, and detaching the mouthpiece from the refillable tank allows the tank to be refilled with e-liquid. The device is activated by a button on the main body. When the device is activated, electrical energy is supplied from the power source to a vaporizer, which heats e-liquid from the tank to produce a vapor which is inhaled by a user through the mouthpiece.

Another approach for a smoking substitute device is the so-called “heat not burn” (“HNB”) approach in which tobacco (rather than e-liquid) is heated or warmed to release vapor. The tobacco may be leaf tobacco or reconstituted tobacco. The vapor may contain nicotine and/or flavorings. In the HNB approach the intention is that the tobacco is heated but not burned, i.e., does not undergo combustion.

A typical HNB smoking substitute device may include a main body and a consumable. The consumable may include the tobacco material. The main body and consumable may be configured to be physically coupled together. In use, heat may be imparted to the tobacco material by a heating device that is typically located in the main body, wherein airflow through the tobacco material causes moisture in the tobacco material to be released as vapor. A vapor may be formed from a carrier in the tobacco material (this carrier may for example include propylene glycol and/or vegetable glycerin) and additionally volatile compounds released from the tobacco. The released vapor may be entrained in the airflow drawn through the tobacco.

As the vapor passes through the smoking substitute device (entrained in the airflow) from an inlet to a mouthpiece (outlet), the vapor cools and condenses to form an aerosol (also referred to as a vapor) for inhalation by the user. The aerosol will normally contain the volatile compounds.

In HNB smoking substitute devices, heating as opposed to burning the tobacco material is believed to cause fewer, or smaller quantities, of the more harmful compounds ordinarily produced during smoking. Consequently, the HNB approach may reduce the odor and/or health risks that can arise through the burning, combustion and pyrolytic degradation of tobacco.

An example of the HNB approach is the IQOS® smoking substitute device from Philip Morris Ltd. The IQOS® smoking substitute device uses a consumable, including reconstituted tobacco located in a wrapper. The consumable includes a holder incorporating a mouthpiece. The consumable may be inserted into a main body that includes a heating device. The heating device has a thermally conductive heating knife which penetrates the reconstituted tobacco of the consumable, when the consumable is inserted into the heating device. Activation of the heating device heats the heating element (in this case a heating knife), which, in turn, heats the tobacco in the consumable. The heating of the tobacco causes it to release nicotine vapor and flavorings which may be drawn through the mouthpiece by the user through inhalation.

A second example of the HNB approach is the device known as “Glo”® from British American Tobacco p.l.c. Glo® comprises a relatively thin consumable. The consumable includes leaf tobacco which is heated by a heating device located in a main body. When the consumable is placed in the main body, the tobacco is surrounded by a heating element of the heating device. Activation of the heating device heats the heating element, which, in turn, heats the tobacco in the consumable. The heating of the tobacco causes it to release nicotine vapor and flavorings which may be drawn through the consumable by the user through inhalation. The tobacco, when heated by the heating device, is configured to produce vapor when heated rather than when burned (as in a smoking apparatus, e.g., a cigarette). The tobacco may contain high levels of aerosol formers (carrier), such as vegetable glycerin (“VG”) or propylene glycol (“PG”).

In prior art smoking substitute devices, some of the un-vaporized e-liquid passes through the wick and to the mouthpiece. This can result in un-vaporized e-liquid passing into the user's mouth, which may be unpleasant for the user. Further leakage occurs due to leakage paths present between the components of the consumable. Additionally, it is desirable to provide consumables which are easier and cheaper to manufacture.

In other prior art smoking substitute devices, airflow through the system can be turbulent and can experience significant pressure drops. This can result in a user needing to provide a significant inhalation force to receive a suitable quantity of aerosol from the system.

The present disclosure has been devised in light of the above considerations.

SUMMARY OF THE DISCLOSURE

First Mode: An Aerosol Delivery Device in which a Turbulence Inducing Element is Configured to Turn Flow Towards a Circumferential Direction

At its most general, a first mode of the present disclosure relates to an aerosol delivery device in which a turbulence inducing element is configured to turn flow towards a circumferential direction.

According to a first aspect of the first mode of the present disclosure, there is provided an aerosol delivery device comprising: a flow passage configured to provide fluid communication between a vaporizer and a mouthpiece aperture, so that the mouthpiece aperture receives a flow comprising an aerosol vapor formed from liquid vaporized by the vaporizer in use; and a turbulence inducing element, the turbulence inducing element located in the flow passage and configured to turn the flow towards a circumferential direction.

Turning the flow induces turbulence in the flow, which causes removal of large drops of liquid from the flow, thereby reducing leakage of liquid into the user's mouth. Turning towards the circumferential direction has been found to be particularly beneficial, because it allows the aerosol flow passage to occupy less volume in the device than if the flow is turned towards an alternative direction.

According to a second aspect of the first mode of the present disclosure, there is provided an aerosol delivery device comprising: a vaporizer configured to form an aerosol vapor from e-liquid; a flow passage configured to provide fluid communication between the vaporizer and a mouthpiece aperture, so that the mouthpiece aperture receives a flow comprising the aerosol vapor in use; a turbulence inducing element, the turbulence inducing element located in the flow passage and configured to induce turbulence in the flow; and a vaporizer chamber containing the vaporizer and the turbulence inducing element, wherein the turbulence inducing element is at least 1 mm downstream of the vaporizer.

Optionally, the turbulence inducing element is configured to turn the flow towards a circumferential direction.

Optionally, the turbulence inducing element of the first or second aspect of the first mode is further configured to turn the flow towards a radial direction.

Advantageously, the turbulence inducing element of the first or second aspect of the first mode comprises a baffle across the flow passage, the baffle forming a first flow obstacle to turn the flow towards the radial direction.

Conveniently, the turbulence inducing element of the first or second aspect of the first mode comprises first and second inlets downstream of the baffle configured to effect branching of the flow.

Optionally, the turbulence inducing element of the first or second aspect of the first mode comprises an upstand, and the flow passage comprises an outlet tube, wherein the outlet tube and the upstand are configured to together form a second flow obstacle to turn the flow towards the circumferential direction.

Advantageously, the second flow obstacle is configured to effect additional branching of the flow.

Conveniently, the turbulence inducing element of the first or second aspect of the first mode comprises an outlet tube, the turbulence inducing element further configured to turn the flow such that the flow is in a substantially axial direction at the outlet tube.

Optionally, the turbulence inducing element of the first or second aspect of the first mode comprises a protrusion forming a third flow obstacle to turn the flow towards the axial direction.

Advantageously, the aerosol delivery device of the first or second aspect of the first mode further comprises a reservoir for storing a liquid, the reservoir in fluid communication with the vaporizer to pass e-liquid to the vaporizer for vaporization.

Conveniently, the reservoir stores the liquid.

Optionally, the liquid is an e-liquid.

Advantageously, the liquid comprises nicotine.

Conveniently, the aerosol delivery device of the first or second aspect of the first mode further comprises a mouthpiece, the mouthpiece comprising the mouthpiece aperture.

Optionally, the aerosol delivery device of the first aspect of the first mode further comprises the vaporizer.

Advantageously, the aerosol delivery device of the first aspect of the first mode further comprises a vaporizer chamber.

Conveniently, the vaporizer chamber containing the vaporizer, wherein the turbulence inducing element of the first or second aspect of the first mode is at least partially located in the vaporizer chamber.

Optionally, the turbulence inducing element of the first aspect of the first mode is located at least 1 mm downstream of the vaporizer.

The turbulence inducing element of the first or second aspect of the first mode may be at least 2 mm downstream of the vaporizer, such as at least 2.5 mm downstream of the vaporizer.

Optionally, the turbulence inducing element of the first or second aspect of the first mode is at most 5 mm downstream of the vaporizer such as at most 4 mm (e.g., substantially 3 mm) downstream of the vaporizer.

Optionally, the aerosol delivery device of the first or second aspect of the first mode is a consumable for a smoking substitute device.

Advantageously, the aerosol delivery device of the first or second aspect of the first mode is a smoking substitute device.

The disclosure includes the combination of the aspects and preferred features of the first mode described except where such a combination is clearly impermissible or expressly avoided.

Second Mode: An Aerosol Delivery Device with an Airflow Path Around an Airflow-Directing Member

At its most general, a second mode of the present disclosure relates to an aerosol delivery device in which an airflow path around an airflow-directing member (baffle) within a vaporizing chamber has a reduced cross-sectional area to match a minimum upstream cross-sectional area of the airflow path in the vaporizing chamber.

In a first aspect of the second mode, there is provided an aerosol delivery device having a chamber airflow path through a vaporizing chamber housing a vaporizer, the chamber airflow path extending through at least one aperture defined by an upstream edge of a transverse baffle mounted downstream from the vaporizer, wherein the chamber airflow path through the at least one aperture has a transverse cross-sectional area that is substantially equal or less than a minimum transverse cross-sectional area of the chamber airflow path downstream from the at least one aperture.

The inclusion of a baffle downstream from the vaporizer may help to reduce (or prevent) un-vaporized liquid from the vaporizer passing to the user. The un-vaporized liquid may collect on an upstream surface of the baffle facing the vaporizer, whilst vapor is able to pass through the aperture(s) defined by the upstream edge of the baffle. Reducing the size of the aperture so that it has an equal or smaller transverse cross-sectional area (perpendicular to the chamber airflow path) than the chamber airflow path downstream of the aperture(s), effectively reduces the surface area of a downstream end wall of the chamber that is exposed to the air flow in the chamber airflow path through the aperture. In this way, it is possible to reduce or eliminate the chance of un-vaporized liquid depositing on this chamber end wall and thus being carried into the airflow downstream of the aperture(s).

The terms “transversely” and “transverse” are used herein in relation to the cross-sectional area of the airflow path to describe a direction that is substantially perpendicular to the airflow path. The terms “transversely” and “transverse” are used herein in relation to components of the device to describe a direction that is substantially perpendicular to the axial (longitudinal) direction of the device.

The device has a device airflow path extending from at least one inlet of the device to an outlet of the device with the vaporizing chamber interposed between the inlet(s) and the outlet. The term “upstream” is used to define a direction towards the inlet(s) of the device. The term “downstream” is used to define a direction towards the outlet of the device.

Optional features of the present disclosure will now be set out. These are applicable singly or in any combination with any aspect of the second mode of the present disclosure.

In some embodiments, the chamber airflow path has a portion extending from the aperture to a downstream edge of the transverse baffle wherein the chamber airflow path at the downstream edge of the transverse baffle has a transverse cross-sectional area that is substantially equal or less than a minimum transverse cross-sectional area of the chamber airflow path downstream from the downstream edge of the transverse baffle.

In some embodiments, the portion of the chamber airflow path extending from the aperture to the downstream edge of the transverse baffle has a constant transverse cross-sectional area.

The chamber airflow path is partly defined by one or more walls of the vaporizing chamber. For example, the at least one aperture may be defined by the upstream edge of the baffle and the opposing sidewall of the chamber.

Where there is a constant transverse cross-sectional area between the aperture and the downstream edge of the baffle, the transverse width of the aperture (i.e., the transverse spacing between the upstream edge of the baffle and the sidewall of the chamber) equals the transverse spacing between the downstream edge of the baffle and the sidewall of the vaporizing chamber.

In some embodiments, the transverse width of the aperture(s) (i.e., the transverse spacing between the upstream edge of the baffle and the sidewall of the chamber) equals (or is less than) the longitudinal spacing between the downstream edge of the baffle and the end wall of the vaporizing chamber.

In some embodiments, the device comprises a passage extending longitudinally from the vaporizing chamber to the outlet of the device. In these embodiments, the chamber airflow path extends to a passage opening which may be provided in a downstream end wall of the vaporizing chamber.

The aperture (and the upstream/downstream edges of the baffle) may be offset transversely (i.e., laterally) from the longitudinal axis of the passage (e.g., may be radially outwards of the passage opening).

In some embodiments, the transverse width of the downstream end wall of the vaporizing chamber between the passage opening and the sidewall of the vaporizing chamber (measured between the radially outermost limit of the passage opening and the proximal sidewall) is less than the length of the chamber airflow path between the upstream edge and the downstream edge of the baffle.

In some embodiments, the chamber airflow path, between the vaporizer and the passage, may comprise at least one deflection. For example, a first portion of the chamber airflow path may extend in a generally longitudinal direction from the vaporizer to the aperture and/or the downstream edge of the baffle. A second portion of the airflow path between the first portion and the passage, may extend generally radially (laterally), e.g., generally parallel to a planar upper surface of the baffle, such that there may be a deflection between the first and second portions.

The device airflow path may comprise a third portion in the passage extending in a generally longitudinal direction. Thus, the device airflow path may deflect between the lateral direction (of the second portion) to a longitudinal direction (of the third portion) at or proximate to the passage opening.

The baffle may have two laterally opposed upstream edges that at least partly define two laterally opposed apertures (e.g., between the upstream edges and opposed sidewalls of the chamber). In this way, the chamber airflow path may be bifurcated as it passes downstream of the vaporizer. In these embodiments, it is preferable that the transverse cross-sectional area of the chamber airflow path in both branches of the bifurcated flow is as described above.

Accordingly, both branches of the bifurcated chamber airflow path may have a transverse cross-sectional area that is substantially equal or less than a minimum transverse cross-sectional area of the chamber airflow path downstream from the apertures.

In some embodiments, both branches of the bifurcated chamber airflow path have an equal transverse cross-sectional area downstream from the apertures.

The baffle may be configured (i.e., shaped and positioned) such that there is no direct longitudinal line of sight between the vaporizer and the passage. A transverse width of the baffle may be substantially the same or greater than a corresponding transverse width (or diameter) of the passage. A transverse cross-sectional area of the baffle may be substantially the same or greater than a transverse cross-sectional area of the passage. A transverse width of the baffle may be greater than 30% of a corresponding transverse width of the chamber, or may, e.g., be greater than 40%, or 50%.

The passage opening (i.e., the opening from the vaporizing chamber into the passage) may have a transverse cross-sectional area of more than 5 mm2. The passage opening may have a transverse cross-sectional area of no more than 10 mm2. The passage opening may have an internal diameter of more than 2.5 mm. The passage opening may have an internal diameter of no more than 4 mm. The transverse cross-sectional area of the or each aperture may be less than the cross-sectional area of the passage opening.

There may be an inlet substantially transversely aligned with the baffle (i.e., both may be aligned along a shared longitudinal axis). The inlet may be substantially transversely aligned with the passage opening (e.g., the inlet may be aligned on the longitudinal axis). The inlet, baffle and passage opening may be aligned along the longitudinal axis.

The vaporizing chamber may comprise opposing parallel sidewalls that are substantially parallel to the longitudinal axis, and a downstream (e.g., end) wall extending transversely between the sidewalls. The passage opening may be formed in the downstream wall of the chamber.

The device may comprise a tank (reservoir) for containing the vaporizable liquid (e.g., an e-liquid) with the vaporizer being in fluid communication with the tank. The e-liquid may, for example, comprise a base liquid and, e.g., nicotine. The base liquid may include propylene glycol and/or vegetable glycerin.

The tank may be defined by a tank housing. At least a portion of the tank housing may be translucent. For example, the tank housing may comprise a window to allow a user to visually assess the quantity of e-liquid in the tank. The tank may be referred to as a “clearomizer” if it includes a window, or a “cartomizer” if it does not.

The passage may extend longitudinally within the tank and a passage wall may define the inner wall of the tank. In this respect, the tank may surround the passage, e.g., the tank may be annular. The passage wall may comprise longitudinal ribs extending there-along. These ribs may provide support to the passage wall. The ribs may extend for the full length of the passage wall. The ribs may project (e.g., radially outwardly) into the tank.

The device may comprise an insert defining the device inlet(s). The insert may be inserted into an open end of the tank so as to seal against the tank housing. The insert may comprise an inner, longitudinally-extending sleeve that defines the wall(s) of the vaporizing chamber and seals against the passage (e.g., seals against outer surfaces of the passage wall). The insert may be configured to support the vaporizer within the vaporizing chamber. The insert may be formed of silicone. The baffle may be formed of silicone. The insert and the baffle may be integrally formed.

The vaporizer may comprise a heater and a wick (e.g., comprising a porous material). The wick may be elongate and extend transversely across the chamber between wall(s) (e.g., sidewalls) of the chamber (which may be defined by the inner sleeve). In order to be in fluid communication with the tank, the wick extends into the tank, e.g., one or both of its opposing transverse ends may extend into the tank, e.g., through the wall(s) of the chamber/through the inner sleeve. In this way e-liquid may be drawn (e.g., by capillary action) along the wick, from the tank to the exposed (central) portion of the wick. The wick may be oriented so as to align (in a direction of the longitudinal axis) with the or each aperture at least partly defined by the baffle (e.g., defined between the upstream edges and wall(s) of the chamber). In this respect, the chamber airflow path may pass around, through or proximal the wick and through the aperture(s). The upstream edge(s) (and downstream edge(s) of the baffle) may extend across the chamber in a direction that is substantially perpendicular to the direction of the extension of the wick.

The heater may comprise a heating element, which may be in the form of a filament wound about the wick (e.g., the filament may extend helically about the wick). The filament may be wound about the exposed portion of the wick. The heating element may be electrically connected (or connectable) to a power source. Thus, in operation, the power source may supply electricity to (i.e., apply a voltage across) the heating element so as to heat the heating element. This may cause liquid stored in the wick (i.e., drawn from the tank) to be heated so as to form a vapor and become entrained in the chamber airflow path. This vapor may subsequently cool to form an aerosol in the vaporizing chamber.

The device may be in the form of a consumable. The consumable may be configured for engagement with a main body (i.e., so as to form a smoking substitute system). For example, the consumable may comprise components of the system that are disposable, and the main body may comprise non-disposable or non-consumable components (e.g., power supply, controller, sensor, etc.) that facilitate the delivery of aerosol by the consumable. In such an embodiment, the aerosol former (e.g., e-liquid) may be replenished by replacing a used consumable with an unused consumable.

The main body and the consumable may be configured to be physically coupled together. For example, the consumable may be at least partially received in a recess of the main body, such that there is snap engagement between the main body and the consumable. Alternatively, the main body and the consumable may be physically coupled together by screwing one onto the other, or through a bayonet fitting.

Thus, the consumable may comprise one or more engagement portions for engaging with a main body. In this way, one end of the device (i.e., the inlet end) may be coupled with the main body, whilst an opposing end (i.e., the outlet end) of the consumable may define a mouthpiece.

The main body or the consumable may comprise a power source or be connectable to a power source. The power source may be electrically connected (or connectable) to the heater. The power source may be a battery (e.g., a rechargeable battery). An external electrical connector in the form of, e.g., a USB port may be provided for recharging this battery.

The consumable may comprise an electrical interface for interfacing with a corresponding electrical interface of the main body. One or both of the electrical interfaces may include one or more electrical contacts. Thus, when the main body is engaged with the consumable, the electrical interface may be configured to transfer electrical power from the power source to a heater of the consumable. The electrical interface may also be used to identify the consumable from a list of known types. The electrical interface may additionally or alternatively be used to identify when the consumable is connected to the main body.

The main body may alternatively or additionally be able to detect information about the consumable via an RFID reader, a barcode or QR code reader. This interface may be able to identify a characteristic (e.g., a type) of the consumable. In this respect, the consumable may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the interface.

The consumable or main body may comprise a controller, which may include a microprocessor. The controller may be configured to control the supply of power from the power source to the heater (e.g., via the electrical contacts). A memory may be provided and may be operatively connected to the controller. The memory may include non-volatile memory. The memory may include instructions which, when implemented, cause the controller to perform certain tasks or steps of a method.

The consumable or main body may comprise a wireless interface, which may be configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface may also be configured to communicate wirelessly with a remote server.

As is provided above, an airflow (i.e., puff) sensor may be provided that is configured to detect a puff (i.e., inhalation from a user). The airflow sensor may be operatively connected to the controller so as to be able to provide a signal to the controller that is indicative of a puff state (i.e., puffing or not puffing). The airflow sensor may, for example, be in the form of a pressure sensor or an acoustic sensor. The controller may control power supply to the heater in response to airflow detection by the sensor. The control may be in the form of activation of the heater in response to a detected airflow. The airflow sensor may form part of the consumable or the main body.

In an alternative embodiment the device may be a non-consumable device in which an aerosol former (e.g., e-liquid) of the system may be replenished by re-filling the tank of the device (rather than replacing the consumable). In this embodiment, the consumable described above may instead be a non-consumable component that is integral with the main body. Thus, the device may comprise the features of the main body described above. In this embodiment, the only consumable portion may be e-liquid contained in the tank of the device. Access to the tank (for re-filling of the e-liquid) may be provided via, e.g., an opening to the tank that is sealable with a closure (e.g., a cap).

The device may be a smoking substitute device (e.g., an e-cigarette device) and, when in the form of a consumable, may be a smoking substitute consumable (e.g., an e-cigarette consumable).

In a second aspect of the second mode there is disclosed a smoking substitute system comprising a main body having a power source, and a consumable as described above with respect to the first aspect of the second mode, the consumable being engageable with the main body such that vaporizer of the consumable is connected to the power source of the main body.

The consumable may be an e-cigarette consumable. The main body may be as described above with respect to the first aspect of the second mode. The main body may, for example, be an e-cigarette device for supplying power to the consumable.

The disclosure includes the combination of the aspects and preferred features of the second mode described except where such a combination is clearly impermissible or expressly avoided.

Third Mode: An Aerosol Delivery Device with an Airflow-Directing Member Having a Sloped Surface

At its most general, a third mode of the present disclosure relates to an aerosol delivery device in which an airflow-directing member (i.e., a baffle) having a sloped surface is provided in an airflow path through the device.

In a first aspect of the third mode there is provided an aerosol delivery device comprising: a vaporizer mounted within a vaporizing chamber for vaporizing a vaporizable liquid; a passage extending along a longitudinal axis from the vaporizing chamber to an outlet of the device; an airflow path extending from an inlet of the device, through the vaporizing chamber and passage, to the outlet; and a baffle interposed between the vaporizer and the passage and comprising a sloped surface for directing airflow within the airflow path towards the passage.

The inclusion of a baffle interposed between the vaporizer and passage may help to reduce (or prevent) un-vaporized liquid from the vaporizer passing into the passage. The un-vaporized liquid may collect on an upstream surface of the baffle facing the vaporizer, whilst vapor is able to flow around the baffle (over the sloped surface) into the passage.

To maximize the protection (from liquid) provided by the baffle, it is desirable to maximize the cross-sectional size of the baffle (i.e., its coverage across the chamber). However, this results in a reduction in the cross-sectional area of the airflow path between the baffle and, e.g., walls of the chamber as it passes from the vaporizer to the passage. This reduction in cross-sectional area results in an increase in the velocity of an airflow along the airflow path, which in turn can result in a higher propensity for un-vaporized liquid (e.g., that is collected on the baffle) to be carried by the airflow into the passage.

In the present disclosure, this reduction in cross-sectional area of the portion of the airflow path (at least partly defined by the baffle) is (at least partly) mitigated by the provision of the sloped surface. The sloped surface provides a larger airflow path (between the baffle and, e.g., walls of the chamber) whilst maintaining the cross-sectional area of an upstream (vaporizer-facing) surface of the baffle. The larger cross-sectional area reduces velocity of an airflow along the airflow path so as to reduce the tendency for un-vaporized liquid to be carried from the vaporizing chamber to the passage.

The term “upstream” is used to define a direction towards the inlet of the device. The term “downstream” is used to define a direction towards the outlet of the device.

Optional features of the present disclosure will now be set out. These are applicable singly or in any combination with any aspect of the third mode of the present disclosure.

The sloped surface at least partly defines a portion of the airflow path. The sloped surface extends obliquely from an upstream transverse edge of the baffle towards the longitudinal axis of the passage. The sloped surface is for directing airflow within the airflow path towards the passage, e.g., towards an opening from the vaporizing chamber to the passage, e.g., towards the longitudinal axis of the passage.

The terms “transversely” and “transverse” are used herein to describe a direction that is substantially perpendicular to the axial (longitudinal) direction of the device.

The sloped surface may be in the form of a chamfered or beveled surface of the baffle. In this respect, the sloped surface may extend from the upstream transverse edge to a downstream transverse edge that is closer to the longitudinal axis than the upstream transverse edge. The sloped surface may be substantially planar, or may be arcuate (i.e., curved). An included angle between the sloped surface and an upstream (i.e., vaporizer-facing) surface of the baffle may be acute. An upstream surface of the baffle (e.g., connected to the sloped surface) may be substantially planar.

In some embodiments a portion of the airflow path at least partly defined by the sloped surface of the baffle may further be at least partly defined by one or more walls of the vaporizing chamber. The sloped surface of the baffle may be (e.g., radially) inwards of the wall(s) of the vaporizing chamber.

The upstream edge of the baffle may at least partly define an aperture through which the airflow path passes. The aperture may be at least partly defined by the wall(s) of the vaporizing chamber. That is, the aperture may be defined between the upstream edge and the wall(s) of the vaporizing chamber. The aperture may be offset transversely (i.e., laterally) from the longitudinal axis of the passage (e.g., may be radially outwards with respect to the passage).

In some embodiments, the airflow path between the vaporizer and the passage, may comprise at least one deflection. For example, a first portion of the airflow path may extend in a generally longitudinal direction from the vaporizer to the aperture. A second portion of the airflow path between the first portion and the passage, may extend generally obliquely (both laterally and longitudinally) and generally parallel to the sloped surface, such that there may be a deflection between the first and second portions. The airflow path may comprise a third portion in the passage extending in a generally longitudinal direction. Thus, the airflow path may deflect from the oblique direction (of the second portion) to a longitudinal direction (of the third portion) at or proximate to an opening to the passage.

The baffle may comprise two sloped surfaces (i.e., each being as described above), the two sloped surfaces being transversely opposed. The two sloped surfaces may have equal and opposite slopes. Where the baffle comprises two sloped surfaces, the baffle may comprise two corresponding upstream edges that at least partly define two corresponding apertures (e.g., between the upstream edges and corresponding wall(s) of the chamber). In this way, the airflow path may be bifurcated so as to comprise two respective branches, each extending through a respective aperture (and between the sloped surfaces and the vaporizing chamber wall(s)).

The baffle extends across (e.g., transversely across) the vaporizing chamber and may be configured (i.e., shaped and positioned) such that there is no direct longitudinal line of sight between the vaporizer and the passage (i.e., an opening to the passage). A transverse width of the baffle may be substantially equal to or greater than a corresponding transverse width (or diameter) of the passage. A transverse cross-sectional area of the baffle may be substantially equal to or greater than a transverse cross-sectional area of the passage. A transverse width of the baffle may be greater than 30% of a corresponding transverse width of the chamber, or may, e.g., be greater than 40%, or 50% of the transverse width of the chamber.

The passage opening (i.e., the opening from the vaporizing chamber into the passage) may have a transverse cross-sectional area of more than 5 mm2. The passage opening may have a transverse cross-sectional area of no more than 10 mm2. The passage opening may have an internal diameter of more than 2.5 mm. The passage opening may have an internal diameter of no more than 4 mm. The transverse cross-sectional area of the or each aperture may be less than the cross-sectional area of the passage opening.

The device may comprise an inlet substantially transversely aligned with the baffle (i.e., both may be aligned along a common longitudinal axis). The inlet may be substantially transversely aligned with the passage opening (e.g., the inlet may be aligned on the longitudinal axis). The inlet, baffle and passage opening may be aligned along the longitudinal axis.

The vaporizing chamber may comprise opposing parallel side walls that are substantially parallel to the longitudinal axis, and a downstream (e.g., end) wall extending transversely between the side walls. The passage opening may be formed in the downstream wall of the chamber.

The device may comprise a tank (reservoir) for containing the vaporizable liquid (e.g., an e-liquid) with the vaporizer being in fluid communication with the tank. The e-liquid may, for example, comprise a base liquid and, e.g., nicotine. The base liquid may include propylene glycol and/or vegetable glycerin.

The tank may be defined by a tank housing. At least a portion of the tank housing may be translucent. For example, the tank housing may comprise a window to allow a user to visually assess the quantity of e-liquid in the tank. The tank may be referred to as a “clearomizer” if it includes a window, or a “cartomizer” if it does not. The passage may extend longitudinally within the tank and a passage wall may define the inner wall of the tank. In this respect, the tank may surround the passage, e.g., the tank may be annular. The passage wall may comprise longitudinal ribs extending there-along. These ribs may provide support to the passage wall. The ribs may extend for the full length of the passage wall. The ribs may project (e.g., radially outwardly) into the tank.

The device may comprise an insert defining the inlet(s). The insert may be inserted into an open end of the tank so as to seal against the tank housing. The insert may comprise an inner, longitudinally-extending sleeve that defines the wall(s) of the vaporizing chamber and seals against the passage (e.g., seals against outer surfaces of the passage wall). The insert may be configured to support the vaporizer within the vaporizing chamber. The insert may be formed of silicone. The baffle may be formed of silicone. The insert and the baffle may be integrally formed.

The vaporizer may comprise a heater and a wick (e.g., comprising a porous material). The wick may be elongate and extend transversely across the chamber between wall(s) (e.g., side walls) of the chamber (which may be defined by the inner sleeve). In order to be in fluid communication with the tank, the wick extends into the tank, e.g., one or both of its opposing transverse ends may extend into the tank, e.g., through the wall(s) of the chamber/through the inner sleeve. In this way e-liquid may be drawn (e.g., by capillary action) along the wick, from the tank to the exposed (central) portion of the wick. The wick may be oriented so as to align (in a direction of the longitudinal axis) with the or each aperture at least partly defined by the baffle (e.g., defined between the upstream edges and wall(s) of the chamber). In this respect, the airflow path may pass around, through or proximate the wick and through the aperture(s). The upstream edge(s) of the baffle may extend across the chamber in a direction that is substantially perpendicular to the direction of the extension of the wick.

The heater may comprise a heating element, which may be in the form of a filament wound about the wick (e.g., the filament may extend helically about the wick). The filament may be wound about the exposed portion of the wick. The heating element may be electrically connected (or connectable) to a power source. Thus, in operation, the power source may supply electricity to (i.e., apply a voltage across) the heating element so as to heat the heating element. This may cause liquid stored in the wick (i.e., drawn from the tank) to be heated so as to form a vapor and become entrained in the chamber portion of the airflow path. This vapor may subsequently cool to form an aerosol in the vaporizing chamber.

The device may be in the form of a consumable. The consumable may be configured for engagement with a main body (i.e., so as to form a smoking substitute system). For example, the consumable may comprise components of the system that are disposable, and the main body may comprise non-disposable or non-consumable components (e.g., power supply, controller, sensor, etc.) that facilitate the delivery of aerosol by the consumable. In such an embodiment, the aerosol former (e.g., e-liquid) may be replenished by replacing a used consumable with an unused consumable.

The main body and the consumable may be configured to be physically coupled together. For example, the consumable may be at least partially received in a recess or cavity of the main body, such that there is snap engagement between the main body and the consumable. Alternatively, the main body and the consumable may be physically coupled together by screwing one onto the other, or through a bayonet fitting.

Thus, the consumable may comprise one or more engagement portions for engaging with the main body. In this way, one end of the device (i.e., the inlet end) may be coupled with the main body, whilst an opposing end (i.e., the outlet end) of the consumable may define a mouthpiece.

The main body may comprise a power source or be connectable to a power source. The power source may be electrically connected (or connectable) to the heater. The power source may be a battery (e.g., a rechargeable battery). An external electrical connector in the form of, e.g., a USB port may be provided for recharging this battery.

The consumable may comprise an electrical interface for interfacing with a corresponding electrical interface of the main body. One or both of the electrical interfaces may include one or more electrical contacts. Thus, when the main body is engaged with the consumable, the electrical interface may be configured to transfer electrical power from the power source to a heater of the consumable. The electrical interface may also be used to identify the consumable from a list of known types. The electrical interface may additionally or alternatively be used to identify when the consumable is connected to the main body.

The main body may alternatively or additionally be able to detect information about the consumable via an RFID reader, a barcode or QR code reader. This interface may be able to identify a characteristic (e.g., a type) of the consumable. In this respect, the consumable may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the interface.

The main body may comprise a controller, which may include a microprocessor. The controller may be configured to control the supply of power from the power source to the heater (e.g., via the electrical contacts). A memory may be provided and may be operatively connected to the controller. The memory may include non-volatile memory. The memory may include instructions which, when implemented, cause the controller to perform certain tasks or steps of a method.

The main body may comprise a wireless interface, which may be configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface may also be configured to communicate wirelessly with a remote server.

As is provided above, an airflow (i.e., puff) sensor may be provided (as part of the main body and/or consumable) that is configured to detect a puff (i.e., inhalation from a user). The airflow sensor may be operatively connected to the controller so as to be able to provide a signal to the controller that is indicative of a puff state (i.e., puffing or not puffing). The airflow sensor may, for example, be in the form of a pressure sensor or an acoustic sensor. The controller may control power supply to the heater in response to airflow detection by the sensor. The control may be in the form of activation of the heater in response to a detected airflow. The airflow sensor may form part of the consumable or the main body.

In an alternative embodiment the device may be a non-consumable device in which an aerosol former (e.g., e-liquid) of the system may be replenished by re-filling the tank of the device (rather than replacing the consumable). In this embodiment, the consumable described above may instead be a non-consumable component that is integral with the main body. Thus, the device may comprise the features of the main body described above. In this embodiment, the only consumable portion may be e-liquid contained in the tank of the device. Access to the tank (for re-filling of the e-liquid) may be provided via, e.g., an opening to the tank that is sealable with a closure (e.g., a cap).

The device may be a smoking substitute device (e.g., an e-cigarette device) and, when in the form of a consumable, may be a smoking substitute consumable (e.g., an e-cigarette consumable).

In a second aspect of the third mode there is disclosed a smoking substitute system comprising a main body having a power source, and a consumable as described above with respect to the first aspect of the third mode, the consumable being engageable with the main body such that vaporizer of the consumable is connected to the power source of the main body.

The consumable may be an e-cigarette consumable. The main body may be as described above with respect to the first aspect. The main body may, for example, be an e-cigarette device for supplying power to the consumable.

The disclosure includes the combination of the aspects and preferred features of the third mode described except where such a combination is clearly impermissible or expressly avoided.

Fourth Mode: An Aerosol Delivery Device in which an Airflow Path Through a Vaporizing Chamber is a Single, Deflected Path

At its most general, a fourth mode of the present disclosure relates to an aerosol delivery device in which an airflow path through a vaporizing chamber is a single, deflected path through a lateral aperture on a transverse baffle.

In a first aspect of the fourth mode, there is provided an aerosol delivery device having a chamber airflow path through a vaporizing chamber housing a vaporizer, the chamber airflow path being a unitary, deflected path extending through a single lateral aperture on a transverse baffle mounted within the vaporizing chamber downstream of the vaporizer.

The inclusion of a baffle downstream of the vaporizer may help to reduce (or prevent) un-vaporized liquid from the vaporizer passing to the user during smoking of the device. The un-vaporized liquid may collect on an upstream surface of the baffle facing the vaporizer, whilst vapor is able to through the aperture in the baffle towards the user.

Known devices have two laterally opposed apertures on the baffle so that vapor can flow in a bifurcated path through the vaporizing chamber. It has been found that the provision of two lateral apertures can result in collection of liquid within one of the apertures during storage on the device on its side (whilst not being vaped). With two holes, liquid can flow into one (under gravity) whilst air within the device is equalized through the other hole. The collected liquid is then inhaled by the user during commencement of vaping. By providing a baffle having only a single lateral aperture, liquid flow into the aperture during storage (and therefore subsequent liquid inhalation) is reduced as air equalization is only possible through the same, single aperture.

The terms “transversely” and “transverse” are used herein in relation to the cross-sectional area of the airflow path to describe a direction that is substantially perpendicular to the airflow path. The terms “transversely” and “transverse” are used herein in relation to components of the device to describe a direction that is substantially perpendicular to the axial (longitudinal) direction of the device.

The device has a device airflow path extending from at least one inlet of the device to an outlet of the device with the vaporizing chamber interposed between the inlet(s) and the outlet. The term “upstream” is used to define a direction towards the inlet(s) of the device. The term “downstream” is used to define a direction towards the outlet of the device.

Optional features of the present disclosure will now be set out. These are applicable singly or in any combination with any aspect of the fourth mode of the present disclosure.

In some embodiments, the aperture is defined by a transverse edge of the baffle. For example, the aperture may be defined by an upstream edge of a transverse baffle mounted downstream from the vaporizer.

The chamber airflow path is partly defined by one or more walls of the vaporizing chamber. For example, the aperture may be defined by the upstream edge of the baffle and a sidewall of the vaporizing chamber facing the upstream edge of the baffle.

The baffle may depend laterally from a sidewall of the vaporizing chamber, i.e., the baffle may extend laterally from the sidewall of the vaporizing chamber that does not define the aperture. Thus, the vaporizing chamber may comprise a first sidewall which (along with the baffle) defines the aperture (and chamber airflow path) and a laterally opposing second sidewall from which the baffle depends.

In some embodiments, the chamber airflow path has a portion extending from the aperture to a downstream edge of the transverse baffle. In some embodiments, the portion of the chamber airflow path extending from the aperture to the downstream edge of the transverse baffle has a constant transverse cross-sectional area. Where there is a constant transverse cross-sectional area between the aperture and the downstream edge of the baffle, the transverse width of the aperture (i.e., the transverse spacing between the upstream edge of the baffle and the first sidewall of the vaporizing chamber) equals the transverse spacing between the downstream edge of the baffle and the first sidewall of the vaporizing chamber.

In some embodiments, the device comprises a passage extending longitudinally from the vaporizing chamber to the outlet of the device. In these embodiments, the chamber airflow path extends to a passage opening which may be provided in a downstream end wall of the vaporizing chamber.

The aperture (and the upstream/downstream edges of the baffle) is/are offset transversely (i.e., laterally) from the longitudinal axis of the passage (e.g., may be radially outwards of the passage opening).

In some embodiments, the chamber airflow path may comprise at least one deflection. The chamber airflow path may comprise a single, undivided chamber airflow path having at least one lateral deflection (e.g., two lateral deflections) between a generally longitudinal portion and a generally radial portion. The chamber airflow path may further comprise at least one axial deflection (e.g., two axial deflections) between a generally radial portion and generally longitudinal portion.

For example, a first portion of the chamber airflow path may extend in a generally longitudinal direction to the vaporizer (e.g., from the inlet(s)) and may be aligned with the axial center of the device. A second portion of the chamber airflow path may then extend generally radially from the vaporizer to the aperture. Thus, there is a first lateral deflection in the chamber airflow path as it passes from the vaporizer to the aperture.

A third portion of the chamber airflow path from the aperture (i.e., the upstream edge of the baffle) to the downstream edge of the baffle may be generally longitudinal and is laterally offset from the axial center of the device. Thus, there is a first axial deflection between the second and third portions of the chamber air flow path.

A fourth portion of the chamber airflow path between the third portion and the passage, may extend generally radially (laterally), e.g., generally parallel to a planar upper surface of the baffle, such that there is a second lateral deflection between the third and fourth portions of the chamber airflow path.

The chamber airflow path may then comprise a second axial deflection from the lateral direction (of the fourth portion) to a longitudinal direction as it leaves the vaporizing chamber at the passage opening.

The baffle may be configured (i.e., shaped and positioned) such that there is no direct longitudinal line of sight between the vaporizer and the passage. A transverse width of the baffle may be substantially the same or greater than a corresponding transverse width (or diameter) of the passage. A transverse cross-sectional area of the baffle may be substantially the same or greater than a transverse cross-sectional area of the passage. A transverse width of the baffle may be greater than 30% of a corresponding transverse width of the vaporizing chamber, or may, e.g., be greater than 40%, or 50%.

The passage opening (i.e., the opening from the vaporizing chamber into the passage) may have a transverse cross-sectional area of more than 5 mm2. The passage opening may have a transverse cross-sectional area of no more than 10 mm2. The passage opening may have an internal diameter of more than 2.5 mm. The passage opening may have an internal diameter of no more than 4 mm. The transverse cross-sectional area of the aperture may be less than the cross-sectional area of the passage opening.

There may be an inlet substantially transversely aligned with the baffle (i.e., both may be aligned along a shared longitudinal axis). The inlet may be substantially transversely aligned with the passage opening (e.g., the inlet may be aligned on the longitudinal axis). The inlet, baffle and passage opening may be aligned along the longitudinal axis.

The vaporizing chamber may comprise opposing first and second parallel sidewalls that are substantially parallel to the longitudinal axis, and a downstream (e.g., end) wall extending transversely between the sidewalls. The passage opening may be formed in the downstream end wall of the vaporizing chamber.

The device may comprise a tank (reservoir) for containing the vaporizable liquid (e.g., an e-liquid) with the vaporizer being in fluid communication with the tank. The e-liquid may, for example, comprise a base liquid and, e.g., nicotine. The base liquid may include propylene glycol and/or vegetable glycerin.

The tank may be defined by a tank housing. At least a portion of the tank housing may be translucent. For example, the tank housing may comprise a window to allow a user to visually assess the quantity of e-liquid in the tank. The tank may be referred to as a “clearomizer” if it includes a window, or a “cartomizer” if it does not.

The passage may extend longitudinally within the tank and a passage wall may define the inner wall of the tank. In this respect, the tank may surround the passage, e.g., the tank may be annular. The passage wall may comprise longitudinal ribs extending there-along. These ribs may provide support to the passage wall. The ribs may extend for the full length of the passage wall. The ribs may project (e.g., radially outwardly) into the tank.

The device may comprise an insert defining the device inlet(s). The insert may be inserted into an open end of the tank so as to seal against the tank housing (e.g., an inside surface of the tank housing). The insert may comprise an inner, longitudinally-extending sleeve that defines the wall(s) of the vaporizing chamber and seals against the passage (e.g., seals against outer surfaces of the passage wall). The insert may be configured to support the vaporizer within the vaporizing chamber. The insert may be formed of silicone. The baffle may be formed of silicone. The insert and the baffle may be integrally formed.

The vaporizer may comprise a heater and a wick (e.g., comprising a porous material). The wick may be elongate and extend transversely across the vaporizing chamber between wall(s) (e.g., between the first and second sidewalls) of the vaporizing chamber (which may be defined by the inner sleeve). In order to be in fluid communication with the tank, the wick extends into the tank, e.g., one or both of its opposing transverse ends may extend into the tank, e.g., through the sidewalls of the vaporizing chamber/through the inner sleeve. In this way e-liquid may be drawn (e.g., by capillary action) along the wick, from the tank to the exposed (central) portion of the wick. The wick may be oriented so as to align (in a direction of the longitudinal axis) with the aperture at least partly defined by the baffle (e.g., defined between the upstream edge and first sidewall of the vaporizing chamber). In this respect, the chamber airflow path may pass around, through or proximal the wick and through the aperture. The upstream edge (and downstream edge of the baffle) may extend across the vaporizing chamber in a direction that is substantially perpendicular to the direction of the extension of the wick.

The heater may comprise a heating element, which may be in the form of a filament wound about the wick (e.g., the filament may extend helically about the wick). The filament may be wound about the exposed portion of the wick. The heating element may be electrically connected (or connectable) to a power source. Thus, in operation, the power source may supply electricity to (i.e., apply a voltage across) the heating element so as to heat the heating element. This may cause liquid stored in the wick (i.e., drawn from the tank) to be heated so as to form a vapor and become entrained in the chamber airflow path. This vapor may subsequently cool to form an aerosol in the vaporizing chamber.

The device may be in the form of a consumable. The consumable may be configured for engagement with a main body (i.e., so as to form a smoking substitute system). For example, the consumable may comprise components of the system that are disposable, and the main body may comprise non-disposable or non-consumable components (e.g., power supply, controller, sensor, etc.) that facilitate the delivery of aerosol by the consumable. In such an embodiment, the aerosol former (e.g., e-liquid) may be replenished by replacing a used consumable with an unused consumable.

The main body and the consumable may be configured to be physically coupled together. For example, the consumable may be at least partially received in a recess of the main body, such that there is snap engagement between the main body and the consumable. Alternatively, the main body and the consumable may be physically coupled together by screwing one onto the other, or through a bayonet fitting.

Thus, the consumable may comprise one or more engagement portions for engaging with a main body. In this way, one end of the device (i.e., the inlet end) may be coupled with the main body, whilst an opposing end (i.e., the outlet end) of the consumable may define a mouthpiece.

The main body or the consumable may comprise a power source or be connectable to a power source. The power source may be electrically connected (or connectable) to the heater. The power source may be a battery (e.g., a rechargeable battery). An external electrical connector in the form of, e.g., a USB port may be provided for recharging this battery.

The consumable may comprise an electrical interface for interfacing with a corresponding electrical interface of the main body. One or both of the electrical interfaces may include one or more electrical contacts. Thus, when the main body is engaged with the consumable, the electrical interface may be configured to transfer electrical power from the power source to a heater of the consumable. The electrical interface may also be used to identify the consumable from a list of known types. The electrical interface may additionally or alternatively be used to identify when the consumable is connected to the main body.

The main body may alternatively or additionally be able to detect information about the consumable via an RFID reader, a barcode or QR code reader. This interface may be able to identify a characteristic (e.g., a type) of the consumable. In this respect, the consumable may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the interface.

The consumable or main body may comprise a controller, which may include a microprocessor. The controller may be configured to control the supply of power from the power source to the heater (e.g., via the electrical contacts). A memory may be provided and may be operatively connected to the controller. The memory may include non-volatile memory. The memory may include instructions which, when implemented, cause the controller to perform certain tasks or steps of a method.

The consumable or main body may comprise a wireless interface, which may be configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface may also be configured to communicate wirelessly with a remote server.

As is provided above, an airflow (i.e., puff) sensor may be provided that is configured to detect a puff (i.e., inhalation from a user). The airflow sensor may be operatively connected to the controller so as to be able to provide a signal to the controller that is indicative of a puff state (i.e., puffing or not puffing). The airflow sensor may, for example, be in the form of a pressure sensor or an acoustic sensor. The controller may control power supply to the heater in response to airflow detection by the sensor. The control may be in the form of activation of the heater in response to a detected airflow. The airflow sensor may form part of the consumable or the main body.

In an alternative embodiment the device may be a non-consumable device in which an aerosol former (e.g., e-liquid) of the system may be replenished by re-filling the tank of the device (rather than replacing the consumable). In this embodiment, the consumable described above may instead be a non-consumable component that is integral with the main body. Thus, the device may comprise the features of the main body described above. In this embodiment, the only consumable portion may be e-liquid contained in the tank of the device. Access to the tank (for re-filling of the e-liquid) may be provided via, e.g., an opening to the tank that is sealable with a closure (e.g., a cap).

The device may be a smoking substitute device (e.g., an e-cigarette device) and, when in the form of a consumable, may be a smoking substitute consumable (e.g., an e-cigarette consumable).

In a second aspect of the fourth mode there is disclosed a smoking substitute system comprising a main body having a power source, and a consumable as described above with respect to the first aspect of the fourth mode, the consumable being engageable with the main body such that vaporizer of the consumable is connected to the power source of the main body.

The consumable may be an e-cigarette consumable. The main body may be as described above with respect to the first aspect. The main body may, for example, be an e-cigarette device for supplying power to the consumable.

The disclosure includes the combination of the aspects and preferred features of the fourth mode described except where such a combination is clearly impermissible or expressly avoided.

Fifth Mode: An Aerosol Delivery Device with an Airflow Path Circumventing a Vaporizer

At its most general, a fifth mode of the present disclosure relates to an aerosol delivery device in which an airflow path through the aerosol delivery device circumvents a vaporizer.

According to a first aspect of the fifth mode, there is provided an aerosol delivery device for a smoking substitute system, the aerosol delivery device comprising a device airflow path extending from at least one inlet of the device to an outlet of the device, and a vaporizer for vaporizing a vaporizable liquid, wherein the device airflow path circumvents the vaporizer.

In this way, the device airflow path does not pass through the vaporizer. Therefore, the possibility of un-vaporized liquid from the vaporizer being entrained in the airflow, and thus through the outlet of the device and into the mouth of a user, is reduced or eliminated.

The terms “transversely” and “transverse” are used herein in relation to components of the device to describe a direction that is substantially perpendicular to the axial (longitudinal) direction of the device.

The device has an upper end comprising the outlet and a lower end comprising the at least one inlet. The device has a longitudinal axis which extends between the upper and lower ends. The term “downstream” used herein is intended to refer to a longitudinal direction of the device towards the outlet. The term “upstream” used herein is intended to refer to a longitudinal direction of the device away from the outlet.

Optional features of the present disclosure will now be set out. These are applicable singly or in any combination with any aspect of the fifth mode of the present disclosure.

The device airflow path may comprise at least one inlet airflow path extending within a respective inlet channel from the at least one inlet to a respective channel opening downstream of the vaporizer such that the chamber airflow path circumvents the vaporizer.

The vaporizer may be disposed within a vaporizing chamber. In these embodiments, the device airflow path comprises at least one inlet airflow path extending from the at least one inlet within a respective inlet channel to the vaporizing chamber, and at least one chamber airflow path extending from the channel through the chamber. As the airflow passes through the vaporizing chamber, vaporized liquid in the vaporizing chamber (which has been vaporized by the vaporizer) may be entrained in the airflow within the chamber airflow path for delivery to the outlet of the device, and therefore to the user.

The or each inlet may be provided on the lowermost surface of the device, e.g., on the lowermost surface of a base portion of the device provided at the lower end of the device.

The or each inlet channel (and the or each inlet airflow path) may extend (e.g., in a generally longitudinal direction) through the base portion of the aerosol delivery device. The or each inlet channel may extend from the respective inlet of the device to a respective inlet channel opening within the vaporizing chamber. Thus, the/each inlet airflow path extends from the respective inlet of the device, through the base portion and through the inlet channel opening into the vaporizing chamber.

In some embodiments, the or each inlet channel opening (and the or each inlet on the lowermost surface of the device/base portion) is offset from the central longitudinal axis of the aerosol delivery device, e.g., off-set in the front to rear direction of the device (which is perpendicular to both the transverse and longitudinal direction).

Where there are two inlet airflow paths, the inlet channel openings (and each inlet on the lowermost surface of the device) may be spaced from each other in the front to rear direction of the device. They may be equally spaced from the central longitudinal axis of the aerosol delivery device on either side of the central longitudinal axis in a front to rear direction. They may be (transversely) aligned with each other in the front to rear direction of the device.

The/each inlet channel opening may be offset from the vaporizer within the vaporizing chamber in the front to rear direction of the device. The/each inlet channel opening may be offset from the vaporizer within the vaporizing chamber in the longitudinal direction of the device. The opening of the/each inlet channel in the vaporizing chamber may be axially downstream of the vaporizer (i.e., closer to the outlet of the device).

In this way, airflow in the inlet airflow path may enter the vaporizing chamber downstream of the vaporizer, which may further help to reduce the amount of un-vaporized liquid entrained in the chamber airflow path towards the outlet of the device.

The vaporizer may be transversely elongated, e.g., it may comprise a transversely elongated wick and a heating element. The vaporizer may be positioned so that it overlies the axial center of the base portion (e.g., it extends transversely to intersect the longitudinal axis of the device).

The opening(s) of the or each inlet channel may be elongated in the transverse direction such that it/they extend substantially parallel to the vaporizer (i.e., the wick of the vaporizer). Accordingly, the or each inlet channel may have a transversely elongated (e.g., substantially rectangular) transverse cross-sectional profile. The cross-sectional profile/area of the inlet channel may be substantially uniform between the respective inlet and channel opening. In this way, the airflow within the inlet channel is substantially laminar.

The lowermost (upstream) surface of the base portion may have a generally rectangular profile with opposing transverse edges spaced by opposing front and rear edges (where the front to rear direction of the device extends perpendicular to both the longitudinal and transverse directions).

The or each inlet on the lowermost surface of the base portion may be elongated in the transverse direction such that it/they extend parallel to the front and rear edges of the lowermost surface of the base portion.

The aerosol delivery device may comprise a tank (reservoir) for containing the vaporizable liquid (e.g., an e-liquid) with the vaporizer being in fluid communication with the tank. The e-liquid may, for example, comprise a base liquid and, e.g., nicotine. The base liquid may include propylene glycol and/or vegetable glycerin.

The tank may be defined by a tank housing. At least a portion of the tank housing may be translucent. For example, the tank may comprise a window to allow a user to visually assess the quantity of e-liquid in the tank. The tank may be referred to as a “clearomizer” if it includes a window, or a “cartomizer” if it does not.

The base portion may be a base insert defining the inlet(s). The base insert may be inserted into an open lower end of the tank so as to seal against an inside surface of the tank housing. The base insert may comprise an inner, longitudinally-extending sleeve that defines wall(s) of the vaporizing chamber. The base insert may be configured to support the vaporizer within the vaporizing chamber. The base insert may define the inlet channels. The base insert may be formed of silicone.

The vaporizing chamber may comprise opposing parallel side walls that are substantially parallel to the longitudinal axis of the device and are spaced by front and rear walls of the chamber, and a downstream wall extending transversely between the side walls (and front to rear between the front and rear walls). The walls of the vaporizing chamber (e.g., the front and rear walls) may have at least one step formed therein, such that a portion of each (front/rear) wall is substantially perpendicular to the longitudinal axis of the device. The step(s) may be provided downstream of the vaporizer within the vaporizing chamber. The opening of the/each inlet channel may be formed in the step(s) of the wall(s) of the vaporizing chamber (i.e., the opening of the/each inlet channel may be formed in the step portion of the wall perpendicular to the longitudinal axis of the device).

The aerosol delivery device may comprise a passage extending to the outlet of the device, e.g., at a mouthpiece of the aerosol delivery device. The passage may extend from a passage opening in the vaporizing chamber to the outlet. In this respect, a user may draw fluid (e.g., air) from the inlet, through the inlet channel(s) and through the vaporizing chamber into the passage opening and through the passage by inhaling at the outlet (i.e., using the mouthpiece).

The passage may comprise passage walls extending within the tank such that the tank may surround the passage. The passage opening may be formed in the downstream wall of the vaporizing chamber. The inner sleeve of the base insert may seal against the passage walls.

The wick may comprise a porous material. The wick may be elongate and extend transversely across the vaporizing chamber between wall(s) (e.g., side walls) of the vaporizing chamber. The wick may also comprise one or more portions in contact with liquid stored in the tank. For example, opposing transverse ends of the wick may protrude into the tank and a central portion (between the ends) may extend across the vaporizing chamber. Thus, fluid may be drawn (e.g., by capillary action) along the wick, from the reservoir to the central portion of the wick.

The filament may be wound about the central portion of the wick. In operation, the power source may supply electricity to (i.e., apply a voltage across) the filament so as to heat the filament. This may cause liquid stored in the wick (i.e., drawn from the tank) to be heated so as to form a vapor and become entrained in the device airflow path. This vapor may subsequently cool to form an aerosol in the passage.

The aerosol delivery device may be in the form of a consumable.

In a second aspect of the fifth mode, there is provided a smoking substitute system comprising: the aerosol delivery device of the first aspect of the fifth mode; and a main body comprising a power source, wherein the power source supplies power to the vaporizer.

The consumable may be configured for engagement with the main body (i.e., so as to form a closed smoking substitute system). For example, the consumable may comprise components of the system that are disposable, and the main body may comprise non-disposable or non-consumable components (e.g., power supply, controller, sensor, etc.) that facilitate the delivery of aerosol by the consumable. In such an embodiment, the aerosol former (e.g., vaporizable e-liquid) may be replenished by replacing a used consumable with an unused consumable.

The main body and the consumable may be configured to be physically coupled together. For example, the consumable may be at least partially received in a recess of the main body, such that there is an interference fit (e.g., snap engagement) between the main body and the consumable. Alternatively, the main body and the consumable may be physically coupled together by screwing one onto the other, or through a bayonet fitting.

Thus, the aerosol delivery device may comprise one or more engagement portions for engaging with a main body. In this way, the lower end of the aerosol delivery device (e.g., the base portion) may be coupled with the main body, whilst the upper end of the aerosol delivery device may define a mouthpiece of the smoking substitute system.

The power source may be electrically connected (or connectable) to the vaporizer of the aerosol delivery device when engaged with the main body. The power source may be a battery (e.g., a rechargeable battery). A connector in the form of, e.g., a USB port may be provided for recharging this battery.

The consumable may comprise an electrical interface for interfacing with a corresponding electrical interface of the main body. A pair of contact pins may comprise the electrical interface for interfacing with a corresponding electrical interface of the main body. One or both of the electrical interfaces may include one or more electrical contacts. Specifically, downstream ends of the contact pins may provide the electrical contacts. Thus, when the main body is engaged with the consumable, the electrical interface may be configured to transfer electrical power from the power source to the heating element of the consumable. The electrical interface may also be used to identify the aerosol delivery device from a list of known types. For example, the consumable may have a certain concentration of nicotine and the electrical interface may be used to identify this. The electrical interface may additionally or alternatively be used to identify when a consumable is connected to the main body.

The main body may comprise an interface, which may, for example, be in the form of an RFID reader, a barcode or QR code reader. This interface may be able to identify a characteristic (e.g., a type) of a consumable engaged with the main body. In this respect, the consumable may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the interface.

The aerosol delivery device or main body may comprise a controller, which may include a microprocessor. The controller may be configured to control the supply of power from the power source to the vaporizer of the aerosol delivery device (e.g., via the electrical contacts). A memory may be provided and may be operatively connected to the controller. The memory may include non-volatile memory. The memory may include instructions which, when implemented, cause the controller to perform certain tasks or steps of a method.

The main body or aerosol delivery device may comprise a wireless interface, which may be configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface may also be configured to communicate wirelessly with a remote server.

A puff sensor (i.e., airflow sensor) may be provided that is configured to detect a puff (i.e., inhalation from a user). The puff sensor may be operatively connected to the controller so as to be able to provide a signal to the controller that is indicative of a puff state (i.e., puffing or not puffing). The puff sensor may, for example, be in the form of a pressure sensor or an acoustic sensor. That is, the controller may control power supply to the heater of the consumable in response to a puff detection by the sensor. The control may be in the form of activation of the vaporizer in response to a detected puff. That is, the aerosol delivery device may be configured to be activated when a puff is detected by the puff sensor. The puff sensor may form part of the consumable or the main body.

In an alternative embodiment the device may be a non-consumable device in which an aerosol former (e.g., e-liquid) of the system may be replenished by re-filling the tank of the device (rather than replacing the consumable). In this embodiment, the consumable described above may instead be a non-consumable component that is integral with the main body. Thus, the device may comprise the features of the main body described above. In this embodiment, the only consumable portion may be e-liquid contained in the tank of the device. Access to the tank (for re-filling of the e-liquid) may be provided via, e.g., an opening to the tank that is sealable with a closure (e.g., a cap).

The disclosure includes the combination of the aspects and preferred features of the fifth mode described except where such a combination is clearly impermissible or expressly avoided.

Sixth Mode: A Smoking Substitute Device Having an Air Inlet

At its most general, a sixth mode of the present disclosure relates to a smoking substitute device having an air inlet arranged to provide a substantially linear/direct airflow path to a vaporizer for use with the device.

In a first aspect of the sixth mode there is provided a smoking substitute device comprising: a body accommodating a power source; one or more side walls projecting longitudinally from an end surface of the body, such that the end surface and the one or more side walls define a cavity for receipt of a vaporizable liquid reservoir and a vaporizer to vaporize the vaporizable liquid; and an air inlet aperture formed in the one or more side walls, the aperture arranged so as to direct air that is external to the device into the cavity in a substantially transverse direction across the end surface.

The provision of an air inlet that directs air transversely across the end surface provides a direct airflow path to the vaporizer. By providing a direct airflow path, as opposed to an airflow path that involves multiple turns/deflections, the pressure drop along the airflow path may be reduced. Similarly, turbulence in the air flow, which can be caused by turns/deflections in the airflow path, may be reduced by providing a more direct airflow. This may result in a reduction in the suction required by a user to draw air into the device and through the vaporizer.

The terms “transversely” and “transverse” are used herein to describe a direction that is substantially perpendicular to the axial (longitudinal) direction of the device.

Optional features of the present disclosure will now be set out. These are applicable singly or in any combination with any aspect of the sixth mode of the present disclosure.

The end surface of the body (i.e., defining a base of the cavity) extends substantially transversely between the side wall(s). The aperture may be positioned so as to be proximate the end surface. For example, the aperture may be spaced from the end surface by a longitudinal distance that is less than 6 mm. The aperture the aperture may be spaced from the end surface by a longitudinal distance that is less than 4 mm, or less than 2 mm. An edge of the aperture may be longitudinally aligned with the end surface (i.e., there may be no longitudinal spacing between the aperture and the end surface).

The aperture may be circular, and may have a diameter of less than, e.g., 2 mm. The aperture may alternatively be in the form of a slot. The slot may extend longitudinally or may be perpendicular to the longitudinal axis. The aperture (or slot) may have a cross-sectional area that is less than 10 mm² or less than 8 mm², or, e.g., less than 5 mm².

The one or more side walls may comprise opposing front and rear walls (or wall portions) and opposing lateral walls (or wall portions) extending between the front and rear walls. The distance between the lateral walls may be greater than the distance between the front and rear walls. The distance between the lateral walls may be, e.g., greater than twice the distance between the front and rear walls.

The aperture may be formed in any one of the front, rear, or lateral walls. The device may comprise two opposing apertures (i.e., each being as described above). For example, each of the lateral walls may comprise an aperture, or each of the front and rear walls may comprise an aperture.

The device may form part of an open smoking substitute system or a closed smoking substitute system. Where the device forms part of a closed smoking substitute system, the device may be configured for engagement (i.e., physical and electrical engagement) with a smoking substitute consumable. In such embodiments, a consumable may be received in the cavity. In that respect the side wall(s) may comprise an engagement portion for engaging a consumable. The engagement portion may be in the form of, e.g., an inwardly extending detent or protrusion for engaging with a recess, lip, aperture, edge, etc. of a consumable.

The device may comprise an electrical interface for electrically interfacing with a consumable received in the cavity. The electrical interface may be electrically connected to the power source, so as to provide power from the power source to the consumable when interfaced therewith. The electrical interface may comprise two (e.g., transversely spaced) electrical contacts projecting longitudinally into the cavity from the end surface of the body (i.e., from the base of the cavity). The electrical contact(s) may project from or through a central portion of the end surface.

In a second aspect of the sixth mode there is disclosed a smoking substitute system comprising: a device according to the first aspect of the sixth mode; a tank for storing vaporizable liquid; a vaporizer for vaporizing the vaporizable liquid, the vaporizer mounted in a vaporizing chamber; and an airflow path extending substantially transversely from the air inlet aperture to an inlet of the vaporizing chamber.

It should be appreciated that the term “substantially transverse” does not require the airflow path to extend exactly transversely. For example, the airflow path may be inclined by a small angle from a transverse axis (e.g., less than 25 degrees, or, e.g., less than 15 degrees, or, e.g., less than 5 degrees). Similarly, a small portion of the airflow path may not be transverse (e.g., less than 10% of the length of the airflow path, or, e.g., less than 5% of the length of the airflow path). In some embodiments, the airflow path may extend transversely (e.g., precisely transversely).

The air flow path may extend between the vaporizer (and/or the vaporizer chamber) and the end surface of the device. The air flow path may extend between the tank and the end surface of the device.

The air inlet aperture may be substantially longitudinally aligned (i.e., share a common transverse reference plane) with the vaporizing chamber, vaporizer and/or the vaporizing chamber inlet, when the consumable is received in the cavity. The aperture may be substantially longitudinally aligned with an upstream end of the consumable when the consumable is received in the cavity.

The vaporizing chamber inlet may be oriented so as to be parallel to a transverse reference plane (i.e., so as to be perpendicular to the air inlet aperture). The vaporizing chamber inlet may, for example, be formed in an upstream (e.g., lower transverse) wall of the vaporizing chamber. In such embodiments, airflow from the transverse airflow path may be redirected at the inlet to a longitudinal direction. Only a single redirection (i.e., turn/deflection) of the airflow may be required between the air inlet aperture and the vaporizer). The term “upstream” is used to define a direction away from the outlet of the device. The term “downstream” is used to define a direction towards the outlet of the device.

In other embodiments, the vaporizing chamber inlet may be oriented so as to be parallel to a longitudinal reference plane (i.e., so as to be parallel to the air inlet aperture). In such embodiments, the vaporizing chamber inlet may, for example, be formed in a lateral wall (extending longitudinally between upstream and downstream walls) of the vaporizing chamber.

The vaporizing chamber may comprise a single (e.g., centrally located inlet), or a plurality of (e.g., two) inlets. Where the vaporizing chamber comprises a plurality of inlets, the airflow path may extend to all of the vaporizing chamber inlets (e.g., the airflow path may comprise branches or may comprise a plenum space).

The system may comprise a passage that extends from the vaporizing chamber to an outlet of the device. An opening to the passage may be formed in a downstream transverse wall of the chamber.

A baffle may be interposed between the vaporizer and the passage. The baffle may extend generally transversely in the vaporizing chamber and may be arranged such that un-vaporized liquid collects on an upstream (e.g., planar) surface of the baffle. The baffle may be aligned with the passage opening (from the vaporizing chamber).

The outlet may form part of a mouthpiece of the device. The mouthpiece may be integrally formed with the passage (i.e., the one or more walls of the passage). The mouthpiece may define an outer surface of the device that is received in a user's mouth in use.

The vaporizer is in fluid communication with the tank so as to be in fluid communication with vaporizable liquid (e.g., e-liquid) in the tank. The e-liquid may, for example, may comprise a base liquid and, e.g., nicotine. The base liquid may include propylene glycol and/or vegetable glycerin.

The tank may be defined by a tank housing. The tank housing may be integrally formed with the mouthpiece and/or the passage. At least a portion of the tank housing may be translucent. For example, the tank housing may comprise a window to allow a user to visually assess the quantity of e-liquid in the tank. The tank may be referred to as a “clearomizer” if it includes a window, or a “cartomizer” if it does not.

The passage may extend longitudinally within the tank and the one or more passage walls may define the inner wall of the tank. In this respect, the tank may surround the passage, e.g., the tank may be annular. The passage wall(s) may comprise longitudinal ribs extending there-along. These ribs may provide support to the passage wall(s). The ribs may extend for the full length of the passage wall(s). The ribs may project (e.g., radially outwardly) into the tank.

The system may comprise an insert, which may define the vaporizing chamber inlet. The insert may be inserted into an open end of the tank so as to seal against the tank housing. The insert may comprise an inner, longitudinally-extending sleeve that defines the wall(s) of the vaporizing chamber and seals against the passage (e.g., seals against outer surfaces of the passage wall(s)). The insert may be configured to support the vaporizer within the vaporizing chamber. The insert may be formed of silicone. The baffle may be formed of silicone. The insert and the baffle may be integrally formed.

The vaporizer may comprise a heater and a wick (e.g., comprising a porous material). The wick may be elongate and extend transversely across the chamber between wall(s) (e.g., side walls) of the chamber (which may be defined by the inner sleeve). So as to be in fluid communication with the tank, the wick extends into the tank, e.g., one or both of its opposing transverse ends may extend into the tank, e.g., through the wall(s) of the chamber/through the inner sleeve. In this way e-liquid may be drawn (e.g., by capillary action) along the wick, from the tank to the exposed (central) portion of the wick. The wick may be oriented so as to be perpendicular to the baffle. In this respect, air may pass around, through or proximate the wick and either side of the baffle.

The heater may comprise a heating element, which may be in the form of a filament wound about the wick (e.g., the filament may extend helically about the wick). The filament may be wound about the exposed portion of the wick. The heating element may be electrically connected (or connectable) to the power source. Thus, in operation, the power source may supply electricity to (i.e., apply a voltage across) the heating element so as to heat the heating element. This may cause liquid stored in the wick (i.e., drawn from the tank) to be heated so as to form a vapor and become entrained in the chamber portion of the airflow path. This vapor may subsequently cool to form an aerosol in the passage or vaporizing chamber.

As is discussed above with respect to the first aspect of the sixth mode, the system may be an open smoking substitute system or a closed smoking substitute system. Where the system is an open smoking substitute system the tank may be refillable, and the tank and vaporizer may be permanently mounted in the cavity defined by the side walls.

On the other hand, when the system is a closed smoking substitute system, the system may comprise a consumable. The consumable may include the tank, vaporizing chamber (and vaporizer) and, e.g., the passage. The consumable may be configured for engagement with the device (i.e., so as to form the smoking substitute system). For example, the consumable may comprise disposable components of the system, whilst the device may comprise non-disposable or non-consumable components (e.g., the power supply, a controller, a sensor, etc.) that facilitate the delivery of aerosol by the consumable. In such an embodiment, the vaporizable liquid may be replenished by replacing a used consumable with an unused consumable.

As is discussed above with respect to the first aspect of the sixth mode, the device and the consumable may be configured to be physically coupled together. For example, the consumable may be at least partly received in the cavity defined by the side wall(s) of the device, such that there is snap engagement between the device and the consumable. Alternatively, the device and the consumable may be physically coupled together by screwing one onto the other, or through a bayonet fitting.

Thus, the consumable may comprise one or more engagement portions for engaging with the device. In this way, one end of the consumable (i.e., an upstream end comprising the vaporizing chamber inlet) may be coupled with the device, whilst an opposing end (i.e., an outlet end) of the consumable may define the mouthpiece.

The airflow path (extending substantially transversely from the air inlet aperture) may extend between the consumable and the device when the consumable is received in the cavity. That is, the airflow path may extend between (and be defined by) the upstream (inlet) end (e.g., defined by the insert) of the consumable and the end surface of the body.

The end surface and/or the upstream end (e.g., underside) of the consumable may comprise guide portions that at least partly define the airflow path so as to guide airflow from the air inlet to the vaporizing chamber inlet. The end surface and/or upstream end of the consumable may comprise a channel for directing air across the end surface. The device or the consumable may comprise spacer portions for spacing the upstream end (and/or inlet) of the consumable from the end surface of the body when the consumable is received in the cavity. The spacer portion may, e.g., be a lip or seat (e.g., extending inwardly from the one or more side walls) on which the consumable is supported above the end surface.

The power source may be a battery (e.g., a rechargeable battery). An external electrical connector in the form of, e.g., a USB port may be provided for recharging this battery. The consumable may comprise an electrical interface for interfacing with the electrical interface of the device. The electrical interface of the consumable may include one or more electrical contacts. Thus, when the device is engaged with the consumable, the electrical interface may be configured to transfer electrical power from the power source to the heater of the consumable. The electrical interface (of the device and/or consumable) may also be used to identify the consumable from a list of known types. The electrical interface (of the device and/or consumable) may additionally or alternatively be used to identify when the consumable is connected to the device.

The device may alternatively or additionally be able to detect information about the consumable via an RFID reader, a barcode or QR code reader. This (information) interface may be able to identify a characteristic (e.g., a type) of the consumable. In this respect, the consumable may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the information interface.

The device may comprise a controller, which may include a microprocessor. The controller may be configured to control the supply of power from the power source to the heater (e.g., via the electrical contacts). A memory may be provided and may be operatively connected to the controller. The memory may include non-volatile memory. The memory may include instructions which, when implemented, cause the controller to perform certain tasks or steps of a method.

The device may comprise a wireless interface, which may be configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface may also be configured to communicate wirelessly with a remote server.

As is provided above, an airflow (i.e., puff) sensor may be provided that is configured to detect a puff (i.e., inhalation from a user). The airflow sensor may be operatively connected to the controller so as to be able to provide a signal to the controller that is indicative of a puff state (i.e., puffing or not puffing). The airflow sensor may, for example, be in the form of a pressure sensor or an acoustic sensor. The controller may control power supply to the heater in response to airflow detection by the sensor. The control may be in the form of activation of the heater in response to a detected airflow. The airflow sensor may form part of the consumable or the device.

The device may be an e-cigarette device and the consumable may be an e-cigarette consumable.

The disclosure includes the combination of the aspects and preferred features of the sixth mode described except where such a combination is clearly impermissible or expressly avoided.

SUMMARY OF THE FIGURES

So that the disclosure may be understood, and so that further aspects and features thereof may be appreciated, embodiments illustrating the principles of the disclosure will now be discussed in further detail with reference to the accompanying figures, in which:

FIG. 1A is a side view of a smoking substitute device of the first mode.

FIG. 1B is a side view of main body of the smoking substitute device of the first mode.

FIG. 1B is a side view of consumable of the smoking substitute device of the first mode.

FIG. 2A is a schematic drawing of the main body of the first mode.

FIG. 2B is a schematic drawing of the consumable of the first mode.

FIG. 3 is a cross-sectional view of the consumable of the first mode.

FIG. 4 is a cross-sectional view of a manufacturing assembly of the first mode.

FIG. 5A is a cross-sectional view of a portion of a second consumable of the first mode.

FIG. 5B is a bottom view of the portion of the second consumable of the first mode.

FIG. 6A is a vertical sectional view of a portion of a third consumable of the first mode.

FIG. 6B is a horizontal sectional view of a portion of the third consumable of the first mode.

FIG. 7A is a front schematic view of a smoking substitute system of the second mode.

FIG. 7B is a front schematic view of a main body of the system of the second mode.

FIG. 7C is a front schematic view of a consumable of the system of the second mode.

FIG. 8A is a schematic of the components of the main body of the second mode.

FIG. 8B is a schematic of the components of the consumable of the second mode.

FIG. 9A is a section view of the consumable of the second mode.

FIG. 9B is a detailed section view of a vaporizing chamber of the consumable of the second mode.

FIG. 10 is a section view of a manufacturing assembly for manufacturing the consumable of the second mode.

FIG. 11A is a front schematic view of a smoking substitute system of the third mode.

FIG. 11B is a front schematic view of a main body of the system of the third mode.

FIG. 11C is a front schematic view of a consumable of the system of the third mode.

FIG. 12A is a schematic of the components of the main body of the third mode.

FIG. 12B is a schematic of the components of the consumable of the third mode.

FIG. 13A is a section view of the consumable of the third mode.

FIG. 13B is a detailed section view of a vaporizing chamber of the consumable of the third mode.

FIG. 14 is a section view of a manufacturing assembly for manufacturing the consumable of the third mode.

FIG. 15A is a front schematic view of a smoking substitute system of the fourth mode.

FIG. 15B is a front schematic view of a main body of the system of the fourth mode.

FIG. 15C is a front schematic view of a consumable of the system of the fourth mode.

FIG. 16A is a schematic of the components of the main body of the fourth mode.

FIG. 16B is a schematic of the components of the consumable of the fourth mode.

FIG. 17A is a section view of the consumable of the fourth mode.

FIG. 17B and FIG. 17C are detailed section views of a vaporizing chamber of the consumable of the fourth mode.

FIG. 18 is a section view of a manufacturing assembly for manufacturing the consumable of the fourth mode.

FIG. 19A is a front schematic view of a smoking substitute system of the fifth mode.

FIG. 19B is a front schematic view of a main body of the system of the fifth mode.

FIG. 19C is a front schematic view of a consumable of the system of the fifth mode.

FIG. 20A is a schematic of the components of the main body of the fifth mode.

FIG. 20B is a schematic of the components of the consumable of the fifth mode.

FIG. 21 is a section view of the consumable of the fifth mode.

FIG. 22A is a perspective view of a base insert of the consumable of the fifth mode.

FIG. 22B is an alternative perspective view of the base insert of FIG. 22A.

FIG. 22C is a section view of the base insert of FIG. 22A.

FIG. 23A is a front schematic view of a smoking substitute system of the sixth mode.

FIG. 23B is a front schematic view of a device of the system of the sixth mode.

FIG. 23C is a front schematic view of a consumable of the system of the sixth mode.

FIG. 24A is a schematic of the components of the device of the sixth mode.

FIG. 24B is a schematic of the components of the consumable of the sixth mode.

FIG. 25A is a schematic section view of the device of the sixth mode.

FIG. 25B is a section view of the consumable engaged with the device of the sixth mode.

FIG. 26 is a section view of a manufacturing assembly for manufacturing the consumable of the sixth mode.

DETAILED DESCRIPTION OF THE FIGURES

First Mode: An Aerosol Delivery Device in which a Turbulence Inducing Element is Configured to Turn Flow Towards a Circumferential Direction

Aspects and embodiments of the first mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

FIG. 1A shows an aerosol delivery device, which is a smoking substitute device 110. In this example, the smoking substitute device 110 includes a main body 120 and a consumable 150. The consumable 150 may alternatively be referred to as a “pod”. The consumable may also be referred to as a cartridge or cartomizer. In other examples, the term “aerosol delivery device” may apply to the consumable 150 alone rather than the smoking substitute device 110.

In this example, the smoking substitute device 110 is a closed system vaping device, wherein the consumable 150 includes a liquid reservoir or sealed tank 156 and is intended for one-use only.

FIG. 1A shows the smoking substitute device 110 with the main body 120 physically coupled to the consumable 150.

FIG. 1B shows the main body 120 of the smoking substitute device 110 without the consumable 150.

FIG. 1C shows the consumable 150 of the smoking substitute device 110 without the main body 120.

The main body 120 and the consumable 150 are configured to be physically coupled together, in this example by pushing the consumable 150 into an aperture in a top end 122 of the main body 120, such that there is an interference fit between the main body 120 and the consumable 150. In other examples, the main body 120 and the consumable could be physically coupled together by screwing one onto the other, or through a bayonet fitting, for example. An optional light 126, e.g., an LED, located behind a small translucent cover, is located a bottom end 124 of the main body 120. The optional light 126 may be configured to illuminate when the smoking substitute device 110 is activated.

The consumable 150 includes a mouthpiece (not shown in FIG. 1A-1C) at a top end 152 of the consumable 150, as well as one or more air inlets (not shown) so that air can be drawn into the smoking substitute device 110 when a user inhales through the mouthpiece. At a bottom end 154 of the consumable 150, there is located a tank 156 that contains e-liquid. The tank 156 may be a translucent body, for example.

The tank 156 preferably includes a window 158, so that the amount of e-liquid in the tank 156 can be visually assessed. The main body 120 includes a slot 128 so that the window 158 of the consumable 150 can be seen whilst the rest of the tank 156 is obscured from view when the consumable 150 is inserted into the aperture in the top end 122 of the main body 120.

The tank 156 may be referred to as a “clearomizer” if it includes a window 158, or a “cartomizer” if it does not.

The consumable 150 may identify itself to the main body 120, via an electrical interface, RFID chip, or barcode.

FIG. 2A is a schematic drawing of the main body 120 of the smoking substitute device 110.

FIG. 2B is a schematic drawing of the consumable 150 of the smoking substitute device 110.

As shown in FIG. 2A, the main body 120 includes a power source 118, a control unit 130, a memory 132, a wireless interface 134, an electrical interface 136, and, optionally, one or more additional components 138.

The power source 118 is preferably a battery, more preferably a rechargeable battery.

The control unit 130 may include a microprocessor, for example.

The memory 132 is preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the control unit 130 to perform certain tasks or steps of a method.

The wireless interface 134 is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 134 could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 134 may also be configured to communicate wirelessly with a remote server.

The electrical interface 136 of the main body 120 may include one or more electrical contacts. The electrical interface 136 may be located in, and preferably at the bottom of, the aperture in the top end 122 of the main body 120. When the main body 120 is physically coupled to the consumable 150, the electrical interface 136 may be configured to pass electrical power from the power source 118 to (e.g., a heating device of) the consumable 150 when the smoking substitute device 110 is activated, e.g., via the electrical interface 160 of the consumable 150 (discussed below). The electrical interface may be configured to receive power from a charging station, when the main body 120 is not physically coupled to the consumable 150 and is instead coupled to the charging station. The electrical interface 136 may also be used to identify the consumable 150 from a list of known consumables. For example, the consumable may be a particular flavor and/or have a certain concentration of nicotine. This can be identified to the control unit 130 of the main body 120 when the consumable is connected to the main body. Additionally, or alternatively, there may be a separate communication interface provided in the main body 120 and a corresponding communication interface in the consumable 150 such that, when connected, the consumable can identify itself to the main body 120.

The additional components 138 of the main body 120 may comprise the optional light 126 discussed above.

The additional components 138 of the main body 120 may, if the power source 118 is a rechargeable battery, comprise a charging port configured to receive power from the charging station. This may be located at the bottom end 124 of the main body 120. Alternatively, the electrical interface 136 discussed above is configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

The additional components 138 of the main body 120 may, if the power source 118 is a rechargeable battery, include a battery charging control circuit, for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in the charging station (if present).

The additional components 138 of the main body 120 may include an airflow sensor for detecting airflow in the smoking substitute device 110, e.g., caused by a user inhaling through a mouthpiece 166 (discussed below) of the smoking substitute device 110. The smoking substitute device 110 may be configured to be activated when airflow is detected by the airflow sensor. This optional sensor could alternatively be included in the consumable 150 (though this is less preferred where the consumable 150 is intended to be disposed of after use, as in this example). The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece or how many times a user draws on the mouthpiece in a particular time period.

The additional components 138 of the main body 120 may include an actuator, e.g., a button. The smoking substitute device 110 may be configured to be activated when the actuator is actuated. This provides an alternative to the airflow sensor noted, as a mechanism for activating the smoking substitute device 110.

As shown in FIG. 2B, the consumable 150 includes the tank 156, an electrical interface 160, a heating device 162, one or more air inlets 164, a mouthpiece 166, and, optionally, one or more additional components 168. The consumable 150 includes a heater chamber 170, which contains the heating device 162.

The electrical interface 160 of the consumable 150 may include one or more electrical contacts. The electrical interface 136 of the main body 120 and an electrical interface 160 of the consumable 150 are preferably configured to contact each other and thereby electrically couple the main body 120 to the consumable 150 when the bottom end 154 of the consumable 150 is inserted into the top end 122 of the main body 120 (as shown in FIG. 1A) to physically coupled the consumable 150 to the main body 120. In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118 in the main body 120 to the heating device 162 in the consumable 150.

The heating device 162 is preferably configured to heat e-liquid contained in the tank 156, e.g., using electrical energy supplied from the power source 118, in order to vaporize the e-liquid. In one example, the heating device 162 includes a heating filament and a wick, wherein a first portion of the wick extends into the tank 156 in order to draw e-liquid out from the tank 156, and wherein the heating filament coils around a second portion of the wick located outside the tank 156. In this example, the heating filament is configured to heat up e-liquid drawn out of the tank 156 by the wick to produce an aerosol vapor.

The one or more air inlets 164 are preferably configured to allow air to be drawn into the smoking substitute device 110, when a user inhales through the mouthpiece 166. When the consumable 150 is physically coupled to the main body 120, the air inlet 164 receives air which flows from the top end 122 of the main body 120, between the main body 120 and the bottom end 154 of the consumable 150.

In use, a user activates the smoking substitute device 110, e.g., through actuating an actuator included in the main body 120 or by inhaling through the mouthpiece 166 as described above. Upon activation, the control unit 130 may supply electrical energy from the power source 118 to the heating device 162 (via electrical interfaces 136, 160), which may cause the heating device 162 to heat e-liquid drawn from the tank 156 to produce a vapor which is inhaled by a user through the mouthpiece 166.

As an example of one of the one or more additional components 168, an interface for obtaining an identifier of the consumable may be provided. As discussed above, this interface may be, for example, an RFID reader, a barcode or QR code reader, or an electronic interface which is able to identify the consumable to the main body. The consumable may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electronic interface in the main body.

Of course, a skilled reader would readily appreciate that the smoking substitute device 110 shown in FIG. 1 and FIG. 2 shows just one example implementation of a smoking substitute device, and that other forms of smoking substitute device could be used.

As another example, an entirely disposable (one use) smoking substitute device could be used as the smoking substitute device.

FIG. 3 shows a cross-sectional view of a consumable 150. The consumable comprises a tank 156 for storing e-liquid, a mouthpiece 166 and an outlet tube 306, which in this example is a chimney or tube. The tank 156 surrounds the outlet tube 306, with the outlet tube extending through a central portion of the tank 156. The outlet tube 306 has a substantially circular cross-section.

The tank 156 is provided by an outer casing of the consumable 150. The outer casing of the consumable 150 comprises a tank wall 304. The tank wall 304 extends completely around the outlet tube 306 to define the tank 156 in the form of an annulus between the outlet tube 306 and the tank wall 304. The tank wall 304 extends from the bottom of the consumable up to the mouthpiece 166. Where the tank wall 304 meets the mouthpiece 166, the mouthpiece 166 has a larger outer width than the tank 156, which means that there is a lip 168 around the bottom of the mouthpiece 166.

The tank wall 304 tapers, which means that it has a thickness which decreases. The thickness of the tank wall 304 decreases along a first demolding direction, as defined below with respect to FIG. 4. The first demolding direction is a downward direction in FIG. 3, which is a direction away from the mouthpiece 166. This means that, aside from a small number of indents (for example, to provide physical connection between the consumable 150 and the main body 120), the thickness of the tank wall 304 generally decreases with increasing distance along the first demolding direction.

The thickness of the tank wall 304 decreases due to internal surfaces of the tank wall 304 being angled to the first demolding direction at a first tank draft angle. Additionally, the thickness of the tank wall 304 decreases due to external surfaces of the tank wall 304 being angled to the first demolding direction at a second tank draft angle.

The first tank draft angle is preferably at least 0.5 degrees, preferably at least 1.0 degrees, preferably at least 1.5 degrees, preferably at least 2.0 degrees, preferably at least 2.5 degrees, preferably at least 3.0 degrees, preferably at least 3.5 degrees.

The second tank draft angle is preferably at least 0.5 degrees, preferably at least 1.0 degrees, preferably at least 1.5 degrees, preferably at least 2.0 degrees, preferably at least 2.5 degrees, preferably at least 3.0 degrees, preferably at least 3.5 degrees.

The first tank draft angle is preferably not more than 3.5 degrees, preferably not more than 3.0 degrees, preferably not more than 2.5 degrees, preferably not more than 2.0 degrees, preferably not more than 1.5 degrees, preferably not more than 1.0 degrees, preferably not more than 0.5 degrees.

The second tank draft angle is preferably not more than 3.5 degrees, preferably not more than 3.0 degrees, preferably not more than 2.5 degrees, preferably not more than 2.0 degrees, preferably not more than 1.5 degrees, preferably not more than 1.0 degrees, preferably not more than 0.5 degrees.

It will be appreciated that the first tank draft angle and the second tank draft angle need not be the same as each other, and may be selected independently according to the above draft angles. In fact, one of the first tank draft angle and the second tank draft angle may be substantially 0 degrees, while the other may vary as described above.

Similarly, the outlet tube 306 comprises an outlet wall 307. The outlet wall 307 extends fully around the circular cross-section of the outlet tube 306 to provide the outlet tube 306. The outlet wall 307 tapers, which means that it has a thickness which decreases. The thickness of the outlet wall 307 decreases along the first demolding direction, as defined below with respect to FIG. 4. As before, the first demolding direction is a downward direction in FIG. 3, which is a direction away from the mouthpiece 166. This means that the thickness of the outlet wall 307 generally decreases along the first demolding direction. The thickness of the outlet wall 307 decreases due to an inner surface of the outlet wall 307 being angled to the first demolding direction at a first outlet draft angle. Additionally, the thickness of the outlet wall 307 decreases due to an external surface of the outlet wall 307 being angled to the first demolding direction at a second outlet draft angle.

The first outlet draft angle is preferably at least 0.5 degrees, preferably at least 1.0 degrees, preferably at least 1.5 degrees, preferably at least 2.0 degrees, preferably at least 2.5 degrees, preferably at least 3.0 degrees, preferably at least 3.5 degrees.

The second outlet draft angle is preferably at least 0.5 degrees, preferably at least 1.0 degrees, preferably at least 1.5 degrees, preferably at least 2.0 degrees, preferably at least 2.5 degrees, preferably at least 3.0, preferably at least 3.5.

The first outlet draft angle is preferably not more than 3.5 degrees, preferably not more than 3.0 degrees, preferably not more than 2.5 degrees, preferably not more than 2.0 degrees, preferably not more than 1.5 degrees, preferably not more than 1.0 degrees, preferably not more than 0.5 degrees.

The second outlet draft angle is preferably not more than 3.5 degrees, preferably not more than 3.0 degrees, preferably not more than 2.5 degrees, preferably not more than 2.0 degrees, preferably not more than 1.5 degrees, preferably not more than 1.0 degrees, preferably not more than 0.5 degrees.

It will be appreciated that the first outlet draft angle and the second outlet draft angle need not be the same as each other, and may be selected independently according to the above draft angles. In fact, one of the first outlet draft angle and the second outlet draft angle may be substantially 0 degrees, while the other may vary as described above.

Similarly, the outlet draft angles and tank draft angles may be selected independently from each other according to the above draft angles.

The outlet tube 306 has an internal width (i.e., a width/diameter of a passage through the outlet tube 306) which generally decreases in a downstream direction (i.e., downstream with respect to the fluid flow when a user inhales, which is an upward direction in FIG. 3). The downstream direction is a direction towards the mouthpiece 166 and, in this example, is an opposite direction to the first demolding direction. This decrease in width occurs due to the second outlet draft angle described above.

A difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is more than 0.10 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is more than 0.12 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is more than 0.14 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is more than 0.16 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is more than 0.18 mm.

The difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is not more than 0.30 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is not more than 0.28 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is not more than 0.26 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is not more than 0.24 mm. More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is not more than 0.22 mm.

More specifically, the difference between the internal width at the downstream end of the outlet tube 306 and the internal width at the upstream end of the outlet tube 306 is substantially 0.20 mm. The outlet tube 306 is substantially 30 mm long. In other examples, the outlet tube 306 may have a length less than 30 mm.

The airway has an internal width less than 5.0 mm at an upstream end of the outlet tube 306. More specifically, the airway has an internal width less than 4.5 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width less than 4.2 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width less than 4.0 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width less than 3.8 mm at the upstream end of the outlet tube 306.

The airway has an internal width greater than 2.0 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 2.5 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 3.0 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 3.2 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 3.4 mm at the upstream end of the outlet tube 306.

More specifically, the airway has an internal width of substantially 3.6 mm at the upstream end of the outlet tube 306.

The airway has an internal width less than 4.8 mm at a downstream end of the outlet tube 306. More specifically, the airway has an internal width less than 4.3 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width less than 4.0 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width less than 3.8 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width less than 3.6 mm at the downstream end of the outlet tube 306.

The airway has an internal width greater than 1.8 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 2.3 mm at the upstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 2.8 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 3.0 mm at the downstream end of the outlet tube 306. More specifically, the airway has an internal width greater than 3.2 mm at the downstream end of the outlet tube 306.

More specifically, the airway has an internal width of substantially 3.4 mm at a downstream end of the outlet tube 306.

The mouthpiece 166 comprises a mouthpiece aperture 314. The outlet tube 306 fluidly connects the heating device 162 to the mouthpiece 166, and, more specifically, the outlet tube 306 fluidly connects the heating device 162 to the mouthpiece aperture 314.

The mouthpiece aperture 314 has a radially inwardly directed inner surface 316. The inner surface 316 of the mouthpiece aperture 314 joins an outer surface 318 of the mouthpiece 166 (i.e., a surface which the user inserts into their mouth in use) at an outer edge 320 of the mouthpiece aperture 314. The outer edge 320 surrounds the mouthpiece aperture 314.

At the outer edge 320, the angle between the inner surface 316 of the mouthpiece aperture 314 and the outer surface 318 of the mouthpiece 166 (i.e., the “mouthpiece angle”) is less than 90 degrees. In the present example, this is due to the outer edge 320 being rounded to define a substantially smooth curve. For the purposes of this disclosure, the rounded portion is considered to be part of the inner surface 316. In this case, where the outer edge 320 is rounded, the mouthpiece angle is substantially 0 degrees. The smooth curve extends between the outer surface 318 and a lower portion of the inner surface 316, the lower portion extending in a substantially downward direction in FIG. 3 (i.e., normal to the outer surface 318 at the outer edge 320 and parallel to the direction of fluid flow in the outlet tube 306).

In the present example, the curve followed by the rounded portion is substantially an arc of a circle. The radius of the rounded portion is preferably less than 1.0 mm. More specifically, the radius of the rounded portion is less than 0.8. More specifically, the radius of the rounded portion is less than 0.6 mm.

The radius of the rounded portion is greater than 0.2 mm. More specifically, the radius of the rounded portion is greater than 0.4 mm.

However, in other examples, the radius of the rounded portion is less than 0.4 mm, and may be less than 0.2 mm. However, the rounded portion need not follow such a curve, and could be any substantially smooth curve.

In other examples, the outer edge 320 is not rounded, and is instead chamfered or beveled, such that the inner surface 316 comprises an angled portion, which extends at constant angle from the outer edge 320. Such a portion may extend the full depth of the mouthpiece aperture 314 (i.e., up to an inner edge 322, where the mouthpiece aperture 314 meets an inner surface of the mouthpiece 166), or may extend only part of the depth of the mouthpiece aperture 314, up to a lower portion extending in the substantially downward direction as described above.

The mouthpiece angle is preferably less than 75 degrees, preferably less than 60 degrees, preferably less than 45 degrees, preferably less than 30 degrees, preferably less than 15 degrees, preferably substantially 0 degrees.

In other examples, the inner surface 316 may comprise a combination of rounded portions and angled portions, and may include several angled portions angled at different angles.

Within the tank 156 there is a heating device 162, which in this example is a coil and wick assembly. The heating device 162 comprises an outer shell with one or more apertures. These apertures are filled with a wick material, so that e-liquid may only ingress the heating device 162 from the tank 156 via capillary action. The wick material passes through or proximal to a coil, which is connected to one or more electrical contacts.

The consumable 150 further comprises a tank seal 308, which seals a bottom portion of the tank 156 beneath the heating device 162. The tank seal 308 is connected to the heating device 162, and the tank seal 308 comprises an air inlet 164, such that air flow is permitted from outside the tank through the air inlet 164 to the heating device 162.

The tank 156, the outlet tube 306 and the mouthpiece 166 are integrally formed with each other. The tank 156, the outlet tube 306 and the mouthpiece 166 make up a single component formed from a continuous piece of material. The tank 156, the outlet tube 306 and the mouthpiece 166 are formed in an injection molding process as described below with respect to FIG. 4. The tank 156, the outlet tube 306 and the mouthpiece 166 are made of a thermoplastic material. More specifically, the tank 156, the outlet tube 306 and the mouthpiece 166 are made of polypropylene.

The outlet tube 306 comprises a filter 310 located within the outlet tube 306. The filter 310 is tubular with an annular cross-section, and an outer surface of the filter 310 is in contact with an inner surface of the outlet tube 306. The outlet tube 306 comprises a void 312, and the filter 310 does not extend into the void 312. The void 312 is a portion of the outlet tube 306 in which no filter is present.

The void 312 comprises a downstream void portion 313 downstream of the filter 310. The downstream portion is located above the filter 310 and below the mouthpiece aperture 314 in FIG. 3. In other examples, the filter 310 extends to the mouthpiece aperture 314. The void 312 further comprises an upstream void portion 315 upstream of the filter 310. The void 312 occupies preferably at least 5% of a total length of the outlet tube 306, preferably at least 10% of the total length of the outlet tube 306, preferably at least 15% of the total length of the outlet tube 306, preferably at least 20% of the total length of the outlet tube 306, preferably at least 25% of the total length of the outlet tube 306.

The void 312 occupies preferably not more than 30% of a total length of the outlet tube 306, preferably not more than 25% of the total length of the outlet tube 306, preferably not more than 20% of the total length of the outlet tube 306, preferably not more than 15% of the total length of the outlet tube 306, preferably not more than 10% of the total length of the outlet tube 306. In this example, the filter 310 has a length of substantially 25 mm.

The outlet tube 306 comprises a retainer (not shown) which retains the filter 310 in position in the outlet tube 306. The retainer comprises a rib, which extends inwardly from an inner surface of the outlet tube to retain the filter in position in the outlet tube by an interference fit.

The filter 310 is made from a fabric, which may be cotton or another fiber. The filter may be formed of a mesh. The filter permits flow of vaporized e-liquid through the filter 310, but prevents flow of un-vaporized e-liquid through the filter 310. This reduces leakage of un-vaporized e-liquid into the user's mouth. The filter 310 may be a gas-permeable and liquid-impermeable membrane.

In use, when the consumable 150 is connected to the main body 120, the user inserts the mouthpiece 166 into their mouth. The user inhales through the mouthpiece aperture 314, which draws air through the air inlet 164 and into the heating device 162.

At the same time, an electrical current is provided to the one or more contacts, which causes heating of the coil, and consequent vaporization of the e-liquid within the wick material. The air flow passes through the coil and wick assembly, drawing with it vaporized e-liquid to form the aerosol vapor. The aerosol vapor flows up the outlet tube 306, before exiting the consumable 150 via mouthpiece aperture 314. The e-liquid only enters the coil and wick assembly via the one or more apertures and then, only via the wick.

As the aerosol vapor flows through the outlet tube 306, it passes the filter 310, which filters un-vaporized e-liquid out of the aerosol vapor. The void 312 provides a portion of the outlet tube 306 for condensation settling. The void 312 provides an unobstructed portion of the inner surface of the outlet tube 306 at which un-vaporized e-liquid which remains in the aerosol vapor downstream of the filter 310 can condense and flow down the inner surface of the outlet tube 306 into the filter 310. This further reduces leakage of un-vaporized e-liquid into the user's mouth.

FIG. 4 shows a drawing of a manufacturing assembly 400 which is used to manufacture the consumable 150. The manufacturing assembly 400 comprises a first mold 402 and a second mold 404.

The first mold 402 has a shape which complements that of a first end (a lower end in FIG. 3) of the integrally formed tank 156, mouthpiece 166 and outlet tube 306. The first mold 402 therefore has a shape which matches the inner surfaces of the tank 156, and the inner and outer surfaces of the outlet tube 306.

The second mold 404 has a shape which complements that of a second end (an upper end in FIG. 4) of the integrally formed tank 156, mouthpiece 166 and outlet tube 306. The second mold 404 therefore has a shape which matches the outer surface 318 of the mouthpiece 166 and the inner surface 316 of the mouthpiece aperture 314.

When the first mold 402 and the second mold 404 are brought together, they define a closed cavity which has the shape of the tank 156, the mouthpiece 166 and the outlet tube 306.

To manufacture the tank 156, the mouthpiece 166 and the outlet tube 306, heated material is injected into the cavity between the first mold 402 and the second mold 404. At this point, the first mold 402 and the second mold 404 meet at a boundary between external surfaces of the mouthpiece 166 and the tank 156.

The material is subsequently cooled, and the first mold 402 and the second mold 404 are separated, with the first mold 402 travelling in the first demolding direction 406 (i.e., away from the second mold 404) and the second mold 404 travelling in a second demolding direction 408 (i.e., away from the first mold 402 and opposite to the first demolding direction 406). For a particular component, a demolding direction is a direction along which a mold which contacts that component is removed during an injection molding process.

The filter 310 is then inserted into the outlet tube 306, and the heating device 162, tank seal 308 and any additional components are inserted into the tank 156. The filter 310 is pushed into the outlet tube 306 through the upstream end of the outlet tube 306. Since the filter 310 is shorter than the outlet tube 306, the outlet tube 306 comprises the void 312.

In some examples (particularly where the void comprises the downstream void portion 313), the filter 310 is pushed into the outlet tube 306 using an insertion tool (not shown), with the insertion tool sized so that the filter 310 is inserted such that the filter 310 does not extend to the downstream end of the outlet tube 306, thereby providing the downstream void portion 313. In other examples, the filter 310 is pushed fully up to the mouthpiece aperture 314, with the filter 310 abutting against the mouthpiece aperture 314, which is narrower than the outlet tube 306.

Referring to FIG. 5A and FIG. 5B, there is shown a portion of a second consumable 500. For clarity, the heating device 162, the tank seal 308 and the filter 310 are omitted from FIG. 5A and FIG. 5B. However, the portion of the second consumable 250 is for use with the heating device 162, tank seal 308, filter 310 and any additional components described above.

The second consumable 500 comprises all of the features of the consumable 150 as described above. Many of the reference numerals relating to those features are omitted from FIG. 5A and FIG. 5B for clarity. However, like reference numerals are used in FIG. 5A and FIG. 5B where features referred to previously are referred to again.

In addition to the features which are common with the consumable 150, the second consumable 500 comprises a support 502. The support 502 comprises a first rib 504 and a second rib 506.

Each of the first and second ribs 504, 506 extends in a radially outward direction (with respect to the central axis of the outlet tube) from an external surface of the outlet wall 307 to an inner surface of the tank wall 304. More specifically, each of the first and second ribs 504, 506 extends to the inner surface of the tank wall 304 at a downstream end of the second consumable 500, where the tank wall 304 is also a wall of the mouthpiece 166.

Each of the first and second ribs 504, 506 also extends from an external surface of a wall of the mouthpiece aperture 314. Since the external surface of the wall of the mouthpiece aperture 314 is continuous with the external surface of the outlet wall 307, each of the first and second ribs 504, 506 connects to the external surfaces of the wall of the mouthpiece aperture and the outlet tube up to the downstream end of the second consumable 500.

As best illustrated in FIG. 5B, the first and second ribs 504, 506 are substantially equally spaced around the outlet tube 306. More specifically, the first and second ribs 504, 506 are spaced from each other by 180 degrees around the central axis of the outlet tube 306. The first and second ribs 504, 506 are substantially aligned with a horizontal (as shown in FIG. 5B) line of symmetry of the outlet tube, and extend along a line equidistant between front and rear portions of the second consumable 500.

The support 502 is formed of the same material as the outlet tube 306 and the tank 156. The support 502 is integrally formed with the tank 156 and the outlet tube 306.

The second consumable 500 operates in the same way as the consumable 150, with the support 502 providing structural support to maintain the outlet tube 306 in alignment with the heating device in use.

The second consumable 500 is manufactured through the same process as that described in FIG. 4, with the manufacturing assembly 400 modified so that the closed cavity formed when the first and second molds 402, 404 are brought together further defines the shape of the support 502. The support 502 provides structural support to the outlet tube 306 during demolding and subsequent assembly of the second consumable 500.

Referring to FIG. 6A and FIG. 6B, there is shown a portion of a third consumable 600. The third consumable 600 comprises all of the features of the second consumable 500 as described above. Many of the reference numerals relating to those features are omitted from FIG. 6A and FIG. 6B for clarity. However, like reference numerals are used in FIG. 6A and FIG. 6B where features referred to previously are referred to again. The third consumable 600 functions in generally the same manner as the second consumable 500, and only the differences are described here.

In addition to the features which are common with the second consumable 500, the third consumable 600 comprises turbulence inducing element 602. The turbulence inducing element 602 is partially located in an end portion of the outlet tube 306. The turbulence inducing element 602 is partially located in the heater chamber 170. The turbulence inducing element 602 is formed from silicone. The turbulence inducing element 602 is held in position by a friction fit with the end portion of the outlet tube 306.

The turbulence inducing element 602 is at least 1 mm downstream of the heating device 162 (i.e., the “vaporizer”). It has been found that positioning the turbulence inducing element 602 at least this distance downstream of the heating device 162 permits the aerosol to fully form before the turbulence inducing element 602 is reached. This means that the turbulence induced by the turbulence inducing element 602 is more effective in breaking up any large droplets formed in the aerosol, which reduces leakage of liquid to the user's mouth.

More specifically, the turbulence inducing element is at least 1.5 mm downstream of the vaporizer. More specifically, the turbulence inducing element is at least 2 mm downstream of the vaporizer. More specifically, the turbulence inducing element is at least 2.5 mm downstream of the vaporizer.

The turbulence inducing element is at most 5 mm downstream of the vaporizer. It has been found that positioning the turbulence inducing element 602 beyond this distance from the vaporizer has little effect on the leakage to the user's mouth. It is therefore desirable to have the turbulence inducing element at most this distance from the vaporizer to provide a more compact consumable. More specifically, the turbulence inducing element is at most 5 mm downstream of the vaporizer. More specifically, the turbulence inducing element is at most 4 mm downstream of the vaporizer. More specifically, the turbulence inducing element is substantially 3 mm downstream of the vaporizer.

The turbulence inducing element 602 comprises a baffle 604. The baffle 604 provides a substantially planar surface positioned normal to a longitudinal axis of the third consumable 600 in a flow path from the heating device 162 to the outlet tube 306. The baffle 604 is a first flow obstacle. The baffle 604 is provided by an in-use lowermost surface of the turbulence inducing element 602.

The turbulence inducing element 602 comprises first and second inlets 606, 608 downstream of the baffle 604. The first and second inlets 606, 608 are in side portions of the turbulence inducing element 602. The first and second inlets 606, 608 are formed by apertures between the baffle 604 and the end portion of the outlet tube 306. The first and second inlets 606, 608 are substantially diametrically opposed. In other examples only one inlet is provided.

The turbulence inducing element 602 comprises first and second upstands 610, 612. Each of the first and second upstands 610, 612 is provided downstream of a respective one of the first and second inlets 606, 608. The first and second upstands 610, 612 extend in a direction substantially normal to the plane of the baffle 604 in a substantially axial direction. The first and second upstands 610, 612 provide substantially circumferential surfaces (i.e., surfaces which extend in a circumferential direction). The circumferential directions are normal to the longitudinal axis of the third consumable 600. The circumferential directions are parallel to the circumference of the outlet tube 306. Each upstand 610, 612 is a second flow obstacle. The first and second upstands 610, 612 are substantially diametrically opposed with respect to the outlet tube 306. The first and second upstands contact the internal surface of the outlet tube 306 to provide the friction fit between the turbulence inducing element 602 and the outlet tube 306.

The turbulence inducing element 602 comprises a protrusion 614. The protrusion 614 extends across a diameter of the outlet tube 306. The protrusion 614 extends along a direction substantially normal to a diameter extending between the first and second upstands 610, 612. The protrusion 614 protrudes parallel to the longitudinal axis of the third consumable 600 to contact the outlet tube 306. The protrusion 614 is a third flow obstacle. The protrusion is of substantially uniform height (measured along the axial direction).

In use, the aerosol vapor flows through the heater chamber 170 and contacts the turbulence inducing element 60. The position of the baffle 604 means that the flow of aerosol contacts the baffle 604 and is turned towards a radial direction. More specifically, the flow branches (i.e., splits into two flow streams) at the baffle 604, with the flow streams turned towards substantially opposite radially outward directions. The radial directions are normal to the longitudinal axis of the third consumable 600. The radial directions are parallel to radii of the outlet tube 306.

The effect of turning towards the radial direction is that the flow has a component in this direction, and is not necessarily parallel to that direction. In the present example, the flow is turned such that it flows in a substantially radial direction, but, in other examples, this is not the case.

As such, after the flow branches at the baffle 604 to form two flow streams, each flow stream flows through a respective one of the first and second inlets 606, 608. Since the first and second inlets 606, 608 are in side portions of the turbulence inducing element 602, the flow turns from radially outward to radially inward to flow through the first and second inlets 606, 608.

In the present example, substantially all of the flow passes through turbulence inducing element 602, and substantially all of the flow is turned by the turbulence inducing element 602 as described.

The first and second upstands 610, 612 cooperate with the end portion of the outlet tube 306 to turn the flow streams towards circumferential directions. The substantially radially inward flow streams contact the circumferential surface of the upstands 610, 612, causing the flow streams to turn towards the circumferential direction. More specifically, each of the flow streams branches again, with each stream splitting into two further flow streams turned towards circumferential directions.

The effect of turning towards the circumferential direction is that the flow has a component in this direction, and is not necessarily parallel to that direction. However, in the present example, the flow is turned such that it is in a substantially radial direction.

The protrusion 614 is therefore configured to turn the flow towards the axial direction within the outlet tube 306, where the flow streams recombine to flow through the outlet tube 306 as before.

The effect of turning towards the axial direction is that the flow has a component in this direction, and is not necessarily parallel to that direction. However, in the present example, the flow is turned such that it flows substantially parallel to a circumferential direction.

Second Mode: An Aerosol Delivery Device with an Airflow Path Around an Airflow-Directing Member

Aspects and embodiments of the second mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

FIG. 7A shows a first embodiment of a smoking substitute system 100 b. In this example, the smoking substitute system 100 b includes a main body 102 b and an aerosol delivery device in the form of a consumable 104 b. The consumable 104 b may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e., open systems), the main body may be integral with the consumable such that the aerosol delivery device incorporates the main body. In such systems, a tank of the aerosol delivery device may be accessible for refilling the device.

In this example, the smoking substitute system 100 b is a closed system vaping system, wherein the consumable 104 b includes a sealed tank 106 b and is intended for single-use only. The consumable 104 b is removably engageable with the main body 102 b (i.e., for removal and replacement). FIG. 7A shows the smoking substitute system 100 b with the main body 102 b physically coupled to the consumable 104 b, FIG. 7B shows the main body 102 b of the smoking substitute system 100 b without the consumable 104 b, and FIG. 7C shows the consumable 104 b of the smoking substitute system 100 b without the main body 102 b.

The main body 102 b and the consumable 104 b are configured to be physically coupled together by pushing the consumable 104 b into a cavity at an upper end 108 b of the main body 102 b, such that there is an interference fit between the main body 102 b and the consumable 104 b. In other examples, the main body 102 b and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.

The consumable 104 b includes a mouthpiece (not shown in FIG. 7A, 1B or 1C) at an upper end 109 b of the consumable 104 b, and one or more air inlets (not shown) in fluid communication with the mouthpiece such that air can be drawn into and through the consumable 104 b when a user inhales through the mouthpiece. The tank 106 b containing e-liquid is located at the lower end 111 b of the consumable 104 b.

The tank 106 b includes a window 112 b, which allows the amount of e-liquid in the tank 106 b to be visually assessed. The main body 102 b includes a slot 114 b so that the window 112 b of the consumable 104 b can be seen whilst the rest of the tank 106 b is obscured from view when the consumable 104 b is inserted into the cavity at the upper end 108 b of the main body 102 b.

The lower end 110 b of the main body 102 b also includes a light 116 b (e.g., an LED) located behind a small translucent cover. The light 116 b may be configured to illuminate when the smoking substitute system 100 b is activated. Whilst not shown, the consumable 104 b may identify itself to the main body 102 b, via an electrical interface, RFID chip, or barcode.

FIG. 8A and FIG. 8B are schematic drawings of the main body 102 b and consumable 104 b. As is apparent from FIG. 8A, the main body 102 b includes a power source 118 b, a controller 120 b, a memory 122 b, a wireless interface 124 b, an electrical interface 126 b, and, optionally, one or more additional components 128 b.

The power source 118 b is preferably a battery, more preferably a rechargeable battery. The controller 120 b may include a microprocessor, for example. The memory 122 b preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120 b to perform certain tasks or steps of a method.

The wireless interface 124 b is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 124 b could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 124 b may also be configured to communicate wirelessly with a remote server.

The electrical interface 126 b of the main body 102 b may include one or more electrical contacts. The electrical interface 126 b may be located in a base of the aperture in the upper end 108 b of the main body 102 b. When the main body 102 b is physically coupled to the consumable 104 b, the electrical interface 126 b is configured to transfer electrical power from the power source 118 b to the consumable 104 b (i.e., upon activation of the smoking substitute system 100 b).

The electrical interface 126 b may be configured to receive power from a charging station when the main body 102 b is not physically coupled to the consumable 104 b and is instead coupled to the charging station. The electrical interface 126 b may also be used to identify the consumable 104 b from a list of known consumables. For example, the consumable 104 b may be a particular flavor and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126 b). This can be indicated to the controller 120 b of the main body 102 b when the consumable 104 b is connected to the main body 102 b. Additionally, or alternatively, there may be a separate communication interface provided in the main body 102 b and a corresponding communication interface in the consumable 104 b such that, when connected, the consumable 104 b can identify itself to the main body 102 b.

The additional components 128 b of the main body 102 b may comprise the light 116 b discussed above.

The additional components 128 b of the main body 102 b may also comprise a charging port (e.g., USB or micro-USB port) configured to receive power from the charging station (i.e., when the power source 118 b is a rechargeable battery). This may be located at the lower end 110 b of the main body 102 b. Alternatively, the electrical interface 126 b discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

The additional components 128 b of the main body 102 b may, if the power source 118 b is a rechargeable battery, include a battery charging control circuit, for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in the charging station (if present).

The additional components 128 b of the main body 102 b may include a sensor, such as an airflow (i.e., puff) sensor for detecting airflow in the smoking substitute system 100 b, e.g., caused by a user inhaling through a mouthpiece 136 b of the consumable 104 b. The smoking substitute system 100 b may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable 104 b. The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece or how many times a user draws on the mouthpiece in a particular time period.

The additional components 128 b of the main body 102 b may include a user input, e.g., a button. The smoking substitute system 100 b may be configured to be activated when a user interacts with the user input (e.g., presses the button). This provides an alternative to the airflow sensor as a mechanism for activating the smoking substitute system 100 b.

As shown in FIG. 8B, the consumable 104 b includes the tank 106 b, an electrical interface 130 b, a vaporizer 132 b, one or more air inlets 134 b, a mouthpiece 136 b, and one or more additional components 138 b.

The electrical interface 130 b of the consumable 104 b may include one or more electrical contacts. The electrical interface 126 b of the main body 102 b and an electrical interface 130 b of the consumable 104 b are configured to contact each other and thereby electrically couple the main body 102 b to the consumable 104 b when the lower end 111 b of the consumable 104 b is inserted into the upper end of the main body 102 b (as shown in FIG. 7A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118 b in the main body 102 b to the vaporizer 132 b in the consumable 104 b.

The vaporizer 132 b is configured to heat and vaporize e-liquid contained in the tank 106 b using electrical energy supplied from the power source 118 b. As will be described further below, the vaporizer 132 b includes a heating filament and a wick. The wick draws e-liquid from the tank 106 b and the heating filament heats the e-liquid to vaporize the e-liquid.

The one or more air inlets 134 b are preferably configured to allow air to be drawn into the smoking substitute system 100 b, when a user inhales through the mouthpiece 136 b. When the consumable 104 b is physically coupled to the main body 102 b, the air inlets 134 b receive air, which flows to the air inlets 134 b along a gap between the main body 102 b and the lower end 111 b of the consumable 104 b.

In operation, a user activates the smoking substitute system 100 b, e.g., through interaction with a user input forming part of the main body 102 b or by inhaling through the mouthpiece 136 b as described above. Upon activation, the controller 120 b may supply electrical energy from the power source 118 b to the vaporizer 132 b (via electrical interfaces 126 b, 130 b), which may cause the vaporizer 132 b to heat e-liquid drawn from the tank 106 b to produce a vapor which is inhaled by a user through the mouthpiece 136 b.

An example of one of the one or more additional components 138 b of the consumable 104 b is an interface for obtaining an identifier of the consumable 104 b. As discussed above, this interface may be, for example, an RFID reader, a barcode, a QR code reader, or an electronic interface which is able to identify the consumable. The consumable 104 b may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electronic interface in the main body 102 b.

It should be appreciated that the smoking substitute system 100 b shown in FIG. 7A to FIG. 8B is just one exemplary implementation of a smoking substitute system. For example, the system could otherwise be in the form of an entirely disposable (single-use) system or an open system in which the tank is refillable (rather than replaceable).

FIG. 9A is a section view of the consumable 104 b described above. The consumable 104 b comprises a tank 106 b for storing e-liquid, a mouthpiece 136 b and a passage 140 b extending along a longitudinal axis of the consumable 104 b. In the illustrated embodiment the passage 140 b is in the form of a tube having a substantially circular transverse cross-section (i.e., transverse to the longitudinal axis). The tank 106 b surrounds the passage 140 b, such that the passage 140 b extends centrally through the tank 106 b.

A tank housing 142 b of the tank 106 b defines an outer casing of the consumable 104 b, whilst a passage wall 144 b defines the passage 140 b. The tank housing 142 b extends from the lower end 111 b of the consumable 104 b to the mouthpiece 136 b at the upper end 109 b of the consumable 104 b. At the junction between the mouthpiece 136 b and the tank housing 142 b, the mouthpiece 136 b is wider than the tank housing 142 b, so as to define a lip 146 b that overhangs the tank housing 142 b. This lip 146 b acts as a stop feature when the consumable 104 b is inserted into the main body 102 b (i.e., by contact with an upper edge of the main body 102 b).

The tank 106 b, the passage 140 b and the mouthpiece 136 b are integrally formed with each other so as to form a single unitary component. As will be described further below with respect to FIG. 10, this component may be formed by way of an injection molding process and, for example, may be formed of a thermoplastic material such as polypropylene.

Although not immediately apparent from the figures, the tank housing 142 b tapers, such that the thickness of the tank housing 142 b decreases in a first demolding direction (as will be discussed further with respect to FIG. 10). In FIG. 9A the first demolding direction is in a downward direction away from the mouthpiece 136 b. This means that, aside from a small number of indents (which provide physical connection between the consumable 104 b and the main body 102 b), the thickness of the tank housing 142 b decreases with increasing distance away from the mouthpiece 136 b. In particular, the tank housing 142 b tapers in this way, because internal and external surfaces of the tank housing 142 b are angled with respect to the first demolding direction. This tapering assists in forming the tank housing 142 b and passage wall 144 b as a single (i.e., unitary) component.

Like the tank housing 142 b, the passage wall 144 b is also tapered such that the thickness of the passage wall 144 b decreases along the first demolding direction. Again, the thickness of the passage wall 144 b decreases due to internal and external surfaces of the passage wall 144 b being angled with respect to the first demolding direction. As a result of the tapering of the passage wall 144 b, the passage 140 b has an internal diameter that decreases in a downstream direction (i.e., an upward direction in FIG. 9A). For example, the passage 140 b has an internal width less than 4.0 mm and greater than 3.0 mm at an upstream end of the passage 140 b (e.g., approximately 3.6 mm). On the other hand, the passage 140 b has an internal width of less than 3.8 mm and greater than 2.8 mm at the downstream end of the passage 140 b (e.g., approximately 3.4 mm).

The mouthpiece 136 b comprises a mouthpiece aperture 148 b defining an outlet of the passage 140 b. The mouthpiece aperture 148 b has a radially inwardly directed inner surface 150 b, which joins an outer surface 152 b of the mouthpiece 136 b (i.e., a surface which contacts a user's lips in use) at an outer edge 154 b of the mouthpiece aperture 148 b. At this outer edge 154 b, the included angle between the inner surface 150 b of the mouthpiece aperture 148 b and the outer surface 152 b of the mouthpiece 136 b (i.e., the “mouthpiece angle”) is greater than 90 degrees. In the illustrated embodiment, this is due to the outer edge 154 b being rounded. This outer edge 154 b may otherwise be chamfered or beveled.

The vaporizer 132 b is located in a vaporizing chamber 156 b of the consumable 104 b. This is best shown in FIG. 9B, which provides a detailed view of the vaporizing chamber 156 b. The vaporizing chamber 156 b is downstream of the air inlet 134 b of the consumable 104 b and is fluidly connected to the mouthpiece aperture 148 b (i.e., outlet) by the passage 140 b. In particular, the passage 140 b extends between the mouthpiece aperture 148 b and a passage opening 158 b from the chamber 156 b. This passage opening 158 b is formed in a downstream (i.e., upper) wall 160 b of the chamber 156 b.

The vaporizer 132 b comprises a porous wick 162 b and a heater filament 164 b coiled around the porous wick 162 b. As is apparent from FIG. 9A and FIG. 9B, the porous wick 162 b extends transversely across the chamber 156 b between sidewalls 166 b of the chamber 156 b which form part of an inner sleeve 168 b of an insert 170 b that defines the lower end 111 b of the consumable 104 b that connects with the main body 102 b. The insert 170 b is inserted into an open lower end of the tank 106 b so as to seal against the tank housing 142 b.

In this way, the inner sleeve 168 b projects into the tank 106 b and seals with the passage 140 b (around the passage wall 144 b) so as to separate the chamber 156 b from the e-liquid in the tank 106 b. Ends of the porous wick 162 b project through apertures in the inner sleeve 168 b and into the tank 106 b so as to be in contact with the e-liquid in the tank 106 b. In this way, e-liquid is transported along the porous wick 162 b (e.g., by capillary action) to a central portion of the porous wick 162 b. The transported e-liquid is heated by the heater filament 164 b (when activated, e.g., by detection of inhalation), which causes the e-liquid to be vaporized and to be entrained in air flowing in the vaporizing chamber 156 b. This vaporized liquid may cool to form an aerosol in the passage 140 b, which may then be inhaled by a user.

In some cases, un-vaporized liquid can be carried by air flowing through the chamber 156 b. This may be undesirable for a user. To reduce or avoid this, the consumable 104 b comprises a baffle 172 b, which is shown in more detail in FIG. 9B. The baffle 172 b extends across the chamber 156 b so as to be interposed between the vaporizer 132 b and the passage opening 158 b. In this way, un-vaporized liquid from the porous wick 162 b may collect on an upstream (i.e., lower) planar surface 174 b of the baffle 172 b rather than entering the passage opening 158 b. The baffle 172 b also causes airflow from the vaporizer 132 b to the passage opening 158 b to be redirected around the baffle 172 b. The baffle 172 b comprises two opposing upstream edges 176 b around which the airflow is redirected. These upstream edges 176 b and the sidewalls 166 b of the chamber 156 b define two respective apertures 178 b spaced either side of the baffle 172 b. The baffle further comprises two downstream edges 179 b.

The chamber air flow path, i.e., the airflow through the vaporizing chamber 156 b from proximal the vaporizer 132 b to the passage opening 158 b extends is bifurcated and has two branches extending through the apertures 178 b in a generally longitudinal direction between the upstream edges 176 b and the downstream edges 179 b. The transverse cross-sectional area of the chamber air flow path as it passes between the upstream and downstream edges 176 b, 179 b is constant within each branch and equal between the two branches. Furthermore, the transverse cross-sectional area of the chamber airflow path between the upstream and downstream edges 176 b, 179 b in each branch is equal to the minimum (smallest) cross-sectional area of the chamber airflow path downstream of the downstream edges 179 b, i.e., between the downstream edges 179 b and the passage opening 158 b. In fact, the chamber airflow path between the apertures 178 b and the passage opening 158 b is constant. The chamber airflow path will deflect radially towards the passage opening 158 b at the downstream edges 179 b.

Although not clear from FIG. 9B, the transverse width of the apertures 178 b equals the longitudinal spacing between the downstream edges 179 b of the baffle 172 b and the end wall 160 b of the vaporizing chamber 156 b. Furthermore, the transverse width of the end wall 160 b of the vaporizing chamber 156 b between the passage opening 158 b and the sidewall 166 b of the vaporizing chamber 156 b (measured between the radially outermost limit of the passage opening 158 b and the proximal sidewall 166 b) is less than the length of the chamber airflow path between the upstream edges 176 b and the downstream edges 179 b of the baffle 172 b.

Upon inhalation by a user at the mouthpiece aperture 148 b, air flows along the bifurcated chamber airflow path around the porous wick 162 b, through the apertures 178 b and into the passage 140 b via the passage opening 158 b.

FIG. 10 shows a drawing of a manufacturing assembly 282 b which is used to manufacture the consumable 104 b. The manufacturing assembly 282 b comprises a first mold 284 b and a second mold 286 b.

The first mold 284 b has a shape which complements that of a first end of the integrally formed tank housing 142 b and mouthpiece 136 b. The first mold 284 b therefore has a shape which matches the inner surfaces defining the tank 106 b.

The second mold 286 b has a shape which complements that of a second end of the integrally formed tank housing 142 b and mouthpiece 136 b. The second mold 286 b has a shape which matches the outer surface of the mouthpiece 136 b and the inner surface of the mouthpiece aperture 148 b.

When the first mold 284 b and the second mold 286 b are brought together, they define a closed cavity which has the shape of the tank housing 142 b, the mouthpiece 136 b and the passage walls 144 b.

To manufacture these components, heated material is injected into the cavity between the first mold 284 b and the second mold 286 b. At this point, the first mold 284 b and the second mold 286 b meet at a boundary between external surfaces of the mouthpiece 136 b and the tank housing 142 b.

The material is subsequently cooled, and the first mold 284 b and the second mold 286 b are separated, with the first mold 284 b travelling in the first demolding direction 288 b (i.e., away from the second mold 286 b) and the second mold 286 b travelling in a second demolding direction 290 b (i.e., away from the first mold 284 b and opposite to the first demolding direction 288 b). For a particular component, a demolding direction is a direction along which a mold which contacts that component is removed during an injection molding process.

The insert 170 b and any additional components are subsequently inserted into the tank 106 b.

Third Mode: An Aerosol Delivery Device with an Airflow-Directing Member Having a Sloped Surface

Aspects and embodiments of the third mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

FIG. 11A shows a first embodiment of a smoking substitute system 100 c. In this example, the smoking substitute system 100 c includes a main body 102 c and an aerosol delivery device in the form of a consumable 104 c. The consumable 104 c may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e., open systems), the main body may be integral with the consumable such that the aerosol delivery device incorporates the main body. In such systems, a tank of the aerosol delivery device may be accessible for refilling the device.

In this example, the smoking substitute system 100 c is a closed system vaping system, wherein the consumable 104 c includes a sealed tank 106 c and is intended for single-use only. The consumable 104 c is removably engageable with the main body 102 c (i.e., for removal and replacement). FIG. 11A shows the smoking substitute system 100 c with the main body 102 c physically coupled to the consumable 104 c, FIG. 11B shows the main body 102 c of the smoking substitute system 100 c without the consumable 104 c, and FIG. 11C shows the consumable 104 c of the smoking substitute system 100 c without the main body 102 c.

The main body 102 c and the consumable 104 c are configured to be physically coupled together by pushing the consumable 104 c into a cavity at an upper end 108 c of the main body 102 c, such that there is an interference fit between the main body 102 c and the consumable 104 c. In other examples, the main body 102 c and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.

The consumable 104 c includes a mouthpiece (not shown in FIG. 11A, 1B or 1C) at an upper end 109 c of the consumable 104 c, and one or more air inlets (not shown) in fluid communication with the mouthpiece such that air can be drawn into and through the consumable 104 c when a user inhales through the mouthpiece. The tank 106 c containing e-liquid is located at the lower end 111 c of the consumable 104 c.

The tank 106 c includes a window 112 c, which allows the amount of e-liquid in the tank 106 c to be visually assessed. The main body 102 c includes a slot 114 c so that the window 112 c of the consumable 104 c can be seen whilst the rest of the tank 106 c is obscured from view when the consumable 104 c is inserted into the cavity at the upper end 108 c of the main body 102 c.

The lower end 110 c of the main body 102 c also includes a light 116 c (e.g., an LED) located behind a small translucent cover. The light 116 c may be configured to illuminate when the smoking substitute system 100 c is activated. Whilst not shown, the consumable 104 c may identify itself to the main body 102 c, via an electrical interface, RFID chip, or barcode.

FIG. 12A and FIG. 12B are schematic drawings of the main body 102 c and consumable 104 c. As is apparent from FIG. 12A, the main body 102 c includes a power source 118 c, a controller 120 c, a memory 122 c, a wireless interface 124 c, an electrical interface 126 c, and, optionally, one or more additional components 128 c.

The power source 118 c is preferably a battery, more preferably a rechargeable battery. The controller 120 c may include a microprocessor, for example. The memory 122 c preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120 c to perform certain tasks or steps of a method.

The wireless interface 124 c is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 124 c could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 124 c may also be configured to communicate wirelessly with a remote server.

The electrical interface 126 c of the main body 102 c may include one or more electrical contacts. The electrical interface 126 c may be located in a base of the aperture in the upper end 108 c of the main body 102 c. When the main body 102 c is physically coupled to the consumable 104 c, the electrical interface 126 c is configured to transfer electrical power from the power source 118 c to the consumable 104 c (i.e., upon activation of the smoking substitute system 100 c).

The electrical interface 126 c may be configured to receive power from a charging station when the main body 102 c is not physically coupled to the consumable 104 c and is instead coupled to the charging station. The electrical interface 126 c may also be used to identify the consumable 104 c from a list of known consumables. For example, the consumable 104 c may be a particular flavor and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126 c). This can be indicated to the controller 120 c of the main body 102 c when the consumable 104 c is connected to the main body 102 c. Additionally, or alternatively, there may be a separate communication interface provided in the main body 102 c and a corresponding communication interface in the consumable 104 c such that, when connected, the consumable 104 c can identify itself to the main body 102 c.

The additional components 128 c of the main body 102 c may comprise the light 116 c discussed above.

The additional components 128 c of the main body 102 c may also comprise a charging port (e.g., USB or micro-USB port) configured to receive power from the charging station (i.e., when the power source 118 c is a rechargeable battery). This may be located at the lower end 110 c of the main body 102 c. Alternatively, the electrical interface 126 c discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

The additional components 128 c of the main body 102 c may, if the power source 118 c is a rechargeable battery, include a battery charging control circuit, for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in the charging station (if present).

The additional components 128 c of the main body 102 c may include a sensor, such as an airflow (i.e., puff) sensor for detecting airflow in the smoking substitute system 100 c, e.g., caused by a user inhaling through a mouthpiece 136 c of the consumable 104 c. The smoking substitute system 100 c may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable 104 c. The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece or how many times a user draws on the mouthpiece in a particular time period.

The additional components 128 c of the main body 102 c may include a user input, e.g., a button. The smoking substitute system 100 c may be configured to be activated when a user interacts with the user input (e.g., presses the button). This provides an alternative to the airflow sensor as a mechanism for activating the smoking substitute system 100 c.

As shown in FIG. 12B, the consumable 104 c includes the tank 106 c, an electrical interface 130 c, a vaporizer 132 c, one or more air inlets 134 c, a mouthpiece 136 c, and one or more additional components 138 c.

The electrical interface 130 c of the consumable 104 c may include one or more electrical contacts. The electrical interface 126 c of the main body 102 c and an electrical interface 130 c of the consumable 104 c are configured to contact each other and thereby electrically couple the main body 102 c to the consumable 104 c when the lower end 111 c of the consumable 104 c is inserted into the upper end 108 c of the main body 102 c (as shown in FIG. 11A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118 c in the main body 102 c to the vaporizer 132 c in the consumable 104 c.

The vaporizer 132 c is configured to heat and vaporize e-liquid contained in the tank 106 c using electrical energy supplied from the power source 118 c. As will be described further below, the vaporizer 132 c includes a heating filament and a wick. The wick draws e-liquid from the tank 106 c and the heating filament heats the e-liquid to vaporize the e-liquid.

The one or more air inlets 134 c are preferably configured to allow air to be drawn into the smoking substitute system 100 c, when a user inhales through the mouthpiece 136 c. When the consumable 104 c is physically coupled to the main body 102 c, the air inlets 134 c receive air, which flows to the air inlets 134 c along a gap between the main body 102 c and the lower end 111 c of the consumable 104 c.

In operation, a user activates the smoking substitute system 100 c, e.g., through interaction with a user input forming part of the main body 102 c or by inhaling through the mouthpiece 136 c as described above. Upon activation, the controller 120 c may supply electrical energy from the power source 118 c to the vaporizer 132 c (via electrical interfaces 126 c, 130 c), which may cause the vaporizer 132 c to heat e-liquid drawn from the tank 106 c to produce a vapor which is inhaled by a user through the mouthpiece 136 c.

An example of one of the one or more additional components 138 c of the consumable 104 c is an interface for obtaining an identifier of the consumable 104 c. As discussed above, this interface may be, for example, an RFID reader, a barcode, a QR code reader, or an electronic interface which is able to identify the consumable. The consumable 104 c may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electronic interface in the main body 102 c.

It should be appreciated that the smoking substitute system 100 c shown in FIG. 11A to FIG. 12B is just one exemplary implementation of a smoking substitute system. For example, the system could otherwise be in the form of an entirely disposable (single-use) system or an open system in which the tank is refillable (rather than replaceable).

FIG. 13A is a section view of the consumable 104 c described above. The consumable 104 c comprises a tank 106 c for storing e-liquid, a mouthpiece 136 c and a passage 140 c extending along a longitudinal axis of the consumable 104 c. In the illustrated embodiment the passage 140 c is in the form of a tube having a substantially circular transverse cross-section (i.e., transverse to the longitudinal axis). The tank 106 c surrounds the passage 140 c, such that the passage 140 c extends centrally through the tank 106 c.

A tank housing 142 c of the tank 106 c defines an outer casing of the consumable 104 c, whilst a passage wall 144 c defines the passage 140 c. The tank housing 142 c extends from the lower end 111 c of the consumable 104 c to the mouthpiece 136 c at the upper end 109 c of the consumable 104 c. At the junction between the mouthpiece 136 c and the tank housing 142 c, the mouthpiece 136 c is wider than the tank housing 142 c, so as to define a lip 146 c that overhangs the tank housing 142 c. This lip 146 c acts as a stop feature when the consumable 104 c is inserted into the main body 102 c (i.e., by contact with an upper edge of the main body 102 c).

The tank 106 c, the passage 140 c and the mouthpiece 136 c are integrally formed with each other so as to form a single unitary component. As will be described further below with respect to FIG. 14, this component may be formed by way of an injection molding process and, for example, may be formed of a thermoplastic material such as polypropylene.

Although not immediately apparent from the figures, the tank housing 142 c tapers, such that the thickness of the tank housing 142 c decreases in a first demolding direction (as will be discussed further with respect to FIG. 14). In FIG. 13A the first demolding direction is in a downward direction away from the mouthpiece 136 c. This means that, aside from a small number of indents (which provide physical connection between the consumable 104 c and the main body 102 c), the thickness of the tank housing 142 c decreases with increasing distance away from the mouthpiece 136 c. In particular, the tank housing 142 c tapers in this way, because internal and external surfaces of the tank housing 142 c are angled with respect to the first demolding direction. This tapering assists in forming the tank housing 142 c and passage wall 144 c as a single (i.e., unitary) component.

Like the tank housing 142 c, the passage wall 144 c is also tapered such that the thickness of the passage wall 144 c decreases along the first demolding direction. Again, the thickness of the passage wall 144 c decreases due to internal and external surfaces of the passage wall 144 c being angled with respect to the first demolding direction. As a result of the tapering of the passage wall 144 c, the passage 140 c has an internal diameter that decreases in a downstream direction (i.e., an upward direction in FIG. 13A). For example, the passage 140 c has an internal width less than 4.0 mm and greater than 3.0 mm at an upstream end of the passage 140 c (e.g., approximately 3.6 mm). On the other hand, the passage 140 c has an internal width of less than 3.8 mm and greater than 2.8 mm at the downstream end of the passage 140 c (e.g., approximately 3.4 mm).

The mouthpiece 136 c comprises a mouthpiece aperture 148 c defining an outlet of the passage 140 c. The mouthpiece aperture 148 c has a radially inwardly directed inner surface 150 c, which joins an outer surface 152 c of the mouthpiece 136 c (i.e., a surface which contacts a user's lips in use) at an outer edge 154 c of the mouthpiece aperture 148 c. At this outer edge 154 c, the included angle between the inner surface 150 c of the mouthpiece aperture 148 c and the outer surface 152 c of the mouthpiece 136 c (i.e., the “mouthpiece angle”) is greater than 90 degrees. In the illustrated embodiment, this is due to the outer edge 154 c being rounded. This outer edge 154 c may otherwise be chamfered or beveled.

The vaporizer 132 c is located in a vaporizing chamber 156 c of the consumable 104 c. This is best shown in FIG. 13B, which provides a detailed view of the vaporizing chamber 156 c. The vaporizing chamber 156 c is downstream of the air inlet 134 c of the consumable 104 c and is fluidly connected to the mouthpiece aperture 148 c (i.e., outlet) by the passage 140 c. In particular, the passage 140 c extends between the mouthpiece aperture 148 c and a passage opening 158 c from the chamber 156 c. This passage opening 158 c is formed in a downstream (i.e., upper) wall 160 c of the chamber 156 c.

The vaporizer 132 c comprises a porous wick 162 c and a heater filament 164 c coiled around the porous wick 162 c. As is apparent from FIG. 13A and FIG. 13B, the porous wick 162 c extends transversely across the chamber 156 c between sidewalls 166 c of the chamber 156 c which form part of an inner sleeve 168 c of an insert 170 c that defines the lower end 111 c of the consumable 104 c that connects with the main body 102 c. The insert 170 c is inserted into an open lower end of the tank 106 c so as to seal against the tank housing 142 c.

In this way, the inner sleeve 168 c projects into the tank 106 c and seals with the passage 140 c (around the passage wall 144 c) so as to separate the chamber 156 c from the e-liquid in the tank 106 c. Ends of the porous wick 162 c project through apertures in the inner sleeve 168 c and into the tank 106 c so as to be in contact with the e-liquid in the tank 106 c. In this way, e-liquid is transported along the porous wick 162 c (e.g., by capillary action) to a central portion of the porous wick 162 c that is exposed to airflow through the chamber 156 c. The transported e-liquid is heated by the heater filament 164 c (when activated, e.g., by detection of inhalation), which causes the e-liquid to be vaporized and to be entrained in air flowing past the porous wick 162 c. This vaporized liquid may cool to form an aerosol in the passage 140 c, which may then be inhaled by a user.

In some cases, un-vaporized liquid can be carried by air flowing through the chamber 156 c. This may be undesirable for a user. To reduce or avoid this, the consumable 104 c comprises a baffle 172 c, which is shown in more detail in FIG. 13B. The baffle 172 c extends transversely across the chamber 156 c so as to be interposed between the vaporizer 132 c and the passage opening 158 c. In this way, un-vaporized liquid from the porous wick 162 c may collect on an upstream (i.e., lower) planar surface 174 c of the baffle 172 c rather than entering the passage opening 158 c. The baffle 172 c also causes airflow from the vaporizer 132 c to the passage opening 158 c to be redirected around the baffle 172 c. The baffle 172 c comprises two opposing transverse edges 176 c around which the airflow is redirected. These transverse edges 176 c and the sidewalls 166 c of the chamber 156 c define two respective apertures 178 c spaced either side of the baffle 172 c. Upon inhalation by a user at the mouthpiece aperture 148 c, air flows along a bifurcated airflow path around the porous wick 162 c, through the apertures 178 c and into the passage 140 c via the passage opening 158 c.

In order to reduce the velocity of the air flowing around the baffle 172 c, the baffle 172 c comprises two sloped surfaces 180 c, which are disposed at a downstream side of the baffle 172 c. Each sloped surface 180 c slopes inwardly (towards the longitudinal axis and the passage opening 158 c) from a respective transverse edge 176 c. The sloped surfaces 180 c are connected by a downstream (i.e., upper) planar surface 182 c of the baffle 172 c such that the baffle 172 c has a generally trapezoidal cross-section (i.e., taken along a longitudinally oriented plane as shown in FIG. 13B).

The presence of the sloped surfaces 180 c provides an increased gap between the baffle 172 c and the sidewalls 166 c when compared to a similar baffle having perpendicular (i.e., non-sloped) edge surfaces. This increased gap lowers the velocity of the air, which results in reduced propensity for the air to carry un-vaporized liquid (e.g., that has collected on the upstream surface of the baffle 172 c) into the passage 140 c. As such, a larger baffle 172 c may be used (so as to provide greater protection to the passage opening 158 c). In the illustrated embodiment, the baffle 172 c has a transverse width that is substantially the same as an inner diameter of the passage 140 c.

FIG. 14 shows a drawing of a manufacturing assembly 282 c which is used to manufacture the consumable 104 c. The manufacturing assembly 282 c comprises a first mold 284 c and a second mold 286 c.

The first mold 284 c has a shape which complements that of a first end of the integrally formed tank housing 142 c and mouthpiece 136 c. The first mold 284 c therefore has a shape which matches the inner surfaces defining the tank 106 c.

The second mold 286 c has a shape which complements that of a second end of the integrally formed tank housing 142 c and mouthpiece 136 c. The second mold 286 c has a shape which matches the outer surface of the mouthpiece 136 c and the inner surface of the mouthpiece aperture 148 c.

When the first mold 284 c and the second mold 286 c are brought together, they define a closed cavity which has the shape of the tank housing 142 c, the mouthpiece 136 c and the passage walls 144 c.

To manufacture these components, heated material is injected into the cavity between the first mold 284 c and the second mold 286 c. At this point, the first mold 284 c and the second mold 286 c meet at a boundary between external surfaces of the mouthpiece 136 c and the tank housing 142 c.

The material is subsequently cooled, and the first mold 284 c and the second mold 286 c are separated, with the first mold 284 c travelling in the first demolding direction 288 c (i.e., away from the second mold 286 c) and the second mold 286 c travelling in a second demolding direction 290 c (i.e., away from the first mold 284 c and opposite to the first demolding direction 288 c). For a particular component, a demolding direction is a direction along which a mold which contacts that component is removed during an injection molding process.

The insert 170 c and any additional components are subsequently inserted into the tank 106 c.

Fourth Mode: An Aerosol Delivery Device in which an Airflow Path Through a Vaporizing Chamber is a Single, Deflected Path

Aspects and embodiments of the fourth mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

FIG. 15A shows a first embodiment of a smoking substitute system 100 d. In this example, the smoking substitute system 100 d includes a main body 102 d and an aerosol delivery device in the form of a consumable 104 d. The consumable 104 d may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e., open systems), the main body may be integral with the consumable such that the aerosol delivery device incorporates the main body. In such systems, a tank of the aerosol delivery device may be accessible for refilling the device.

In this example, the smoking substitute system 100 d is a closed system vaping system, wherein the consumable 104 d includes a sealed tank 106 d and is intended for single-use only. The consumable 104 d is removably engageable with the main body 102 d (i.e., for removal and replacement). FIG. 15A shows the smoking substitute system 100 d with the main body 102 d physically coupled to the consumable 104 d, FIG. 15B shows the main body 102 d of the smoking substitute system 100 d without the consumable 104 d, and FIG. 15C shows the consumable 104 d of the smoking substitute system 100 d without the main body 102 d.

The main body 102 d and the consumable 104 d are configured to be physically coupled together by pushing the consumable 104 d into a cavity at an upper end 108 d of the main body 102 d, such that there is an interference fit between the main body 102 d and the consumable 104 d. In other examples, the main body 102 d and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.

The consumable 104 d includes a mouthpiece (not shown in FIG. 15A, 1B or 1C) at an upper end 109 d of the consumable 104 d, and one or more air inlets (not shown) in fluid communication with the mouthpiece such that air can be drawn into and through the consumable 104 d when a user inhales through the mouthpiece. The tank 106 d containing e-liquid is located at the lower end 111 d of the consumable 104 d.

The tank 106 d includes a window 112 d, which allows the amount of e-liquid in the tank 106 d to be visually assessed. The main body 102 d includes a slot 114 d so that the window 112 d of the consumable 104 d can be seen whilst the rest of the tank 106 d is obscured from view when the consumable 104 d is inserted into the cavity at the upper end 108 d of the main body 102 d.

The lower end 110 d of the main body also includes a light 116 d (e.g., an LED) located behind a small translucent cover. The light 116 d may be configured to illuminate when the smoking substitute system 100 d is activated. Whilst not shown, the consumable 104 d may identify itself to the main body 102 d, via an electrical interface, RFID chip, or barcode.

FIG. 16A and FIG. 16B are schematic drawings of the main body 102 d and consumable 104 d. As is apparent from FIG. 16A, the main body 102 d includes a power source 118 d, a controller 120 d, a memory 122 d, a wireless interface 124 d, an electrical interface 126 d, and, optionally, one or more additional components 128 d.

The power source 118 d is preferably a battery, more preferably a rechargeable battery. The controller 120 d may include a microprocessor, for example. The memory 122 d preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120 d to perform certain tasks or steps of a method.

The wireless interface 124 d is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 124 d could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 124 d may also be configured to communicate wirelessly with a remote server.

The electrical interface 126 d of the main body 102 d may include one or more electrical contacts. The electrical interface 126 d may be located in a base of the aperture in the upper end 108 d of the main body 102 d. When the main body 102 d is physically coupled to the consumable 104 d, the electrical interface 126 d is configured to transfer electrical power from the power source 118 d to the consumable 104 d (i.e., upon activation of the smoking substitute system 100 d).

The electrical interface 126 d may be configured to receive power from a charging station when the main body 102 d is not physically coupled to the consumable 104 d and is instead coupled to the charging station. The electrical interface 126 d may also be used to identify the consumable 104 d from a list of known consumables. For example, the consumable 104 d may be a particular flavor and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126 d). This can be indicated to the controller 120 d of the main body 102 d when the consumable 104 d is connected to the main body 102 d. Additionally, or alternatively, there may be a separate communication interface provided in the main body 102 d and a corresponding communication interface in the consumable 104 d such that, when connected, the consumable 104 d can identify itself to the main body 102 d.

The additional components 128 d of the main body 102 d may comprise the light 116 d discussed above.

The additional components 128 d of the main body 102 d may also comprise a charging port (e.g., USB or micro-USB port) configured to receive power from the charging station (i.e., when the power source 118 d is a rechargeable battery). This may be located at the lower end 110 d of the main body 102 d. Alternatively, the electrical interface 126 d discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

The additional components 128 d of the main body 102 d may, if the power source 118 d is a rechargeable battery, include a battery charging control circuit, for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in the charging station (if present).

The additional components 128 d of the main body 102 d may include a sensor, such as an airflow (i.e., puff) sensor for detecting airflow in the smoking substitute system 100 d, e.g., caused by a user inhaling through a mouthpiece 136 d of the consumable 104 d. The smoking substitute system 100 d may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable 104 d. The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece or how many times a user draws on the mouthpiece in a particular time period.

The additional components 128 d of the main body 102 d may include a user input, e.g., a button. The smoking substitute system 100 d may be configured to be activated when a user interacts with the user input (e.g., presses the button). This provides an alternative to the airflow sensor as a mechanism for activating the smoking substitute system 100 d.

As shown in FIG. 16B, the consumable 104 d includes the tank 106 d, an electrical interface 130 d, a vaporizer 132 d, one or more air inlets 134 d, a mouthpiece 136 d, and one or more additional components 138 d.

The electrical interface 130 d of the consumable 104 d may include one or more electrical contacts. The electrical interface 126 d of the main body 102 d and an electrical interface 130 d of the consumable 104 d are configured to contact each other and thereby electrically couple the main body 102 d to the consumable 104 d when the lower end 111 d of the consumable 104 d is inserted into the upper end 108 d of the main body 102 d (as shown in FIG. 15A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118 d in the main body 102 d to the vaporizer 132 d in the consumable 104 d.

The vaporizer 132 d is configured to heat and vaporize e-liquid contained in the tank 106 d using electrical energy supplied from the power source 118 d. As will be described further below, the vaporizer 132 d includes a heating filament and a wick. The wick draws e-liquid from the tank 106 d and the heating filament heats the e-liquid to vaporize the e-liquid.

The one or more air inlets 134 d are preferably configured to allow air to be drawn into the smoking substitute system 100 d, when a user inhales through the mouthpiece 136 d. When the consumable 104 d is physically coupled to the main body 102 d, the air inlets 134 d receive air, which flows to the air inlets 134 d along a gap between the main body 102 d and the lower end 110 d of the consumable 104 d.

In operation, a user activates the smoking substitute system 100 d, e.g., through interaction with a user input forming part of the main body 102 d or by inhaling through the mouthpiece 136 d as described above. Upon activation, the controller 120 d may supply electrical energy from the power source 118 d to the vaporizer 132 d (via electrical interfaces 126 d, 130 d), which may cause the vaporizer 132 d to heat e-liquid drawn from the tank 106 d to produce a vapor which is inhaled by a user through the mouthpiece 136 d.

An example of one of the one or more additional components 138 d of the consumable 104 d is an interface for obtaining an identifier of the consumable 104 d. As discussed above, this interface may be, for example, an RFID reader, a barcode, a QR code reader, or an electronic interface which is able to identify the consumable. The consumable 104 d may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electronic interface in the main body 102 d.

It should be appreciated that the smoking substitute system 100 d shown in FIG. 15A to FIG. 16B is just one exemplary implementation of a smoking substitute system. For example, the system could otherwise be in the form of an entirely disposable (single-use) system or an open system in which the tank is refillable (rather than replaceable).

FIG. 17A is a section view of the consumable 104 d described above. The consumable 104 d comprises a tank 106 d for storing e-liquid, a mouthpiece 136 d and a passage 140 d extending along a longitudinal axis of the consumable 104 d. In the illustrated embodiment the passage 140 d is in the form of a tube having a substantially circular transverse cross-section (i.e., transverse to the longitudinal axis). The tank 106 d surrounds the passage 140 d, such that the passage 140 d extends centrally through the tank 106 d.

A tank housing 142 d of the tank 106 d defines an outer casing of the consumable 104 d, whilst a passage wall 144 d defines the passage 140 d. The tank housing 142 d extends from the lower end 111 d of the consumable 104 d to the mouthpiece 136 d at the upper end 109 d of the consumable 104 d. At the junction between the mouthpiece 136 d and the tank housing 142 d, the mouthpiece 136 d is wider than the tank housing 142 d, so as to define a lip 146 d that overhangs the tank housing 142 d. This lip 146 d acts as a stop feature when the consumable 104 d is inserted into the main body 102 d (i.e., by contact with an upper edge of the main body 102 d).

The tank 106 d, the passage 140 d and the mouthpiece 136 d are integrally formed with each other so as to form a single unitary component. As will be described further below with respect to FIG. 18, this component may be formed by way of an injection molding process and, for example, may be formed of a thermoplastic material such as polypropylene.

Although not immediately apparent from the figures, the tank housing 142 d tapers, such that the thickness of the tank housing 142 d decreases in a first demolding direction (as will be discussed further with respect to FIG. 18). In FIG. 17A the first demolding direction is in a downward direction away from the mouthpiece 136 d. This means that, aside from a small number of indents (which provide physical connection between the consumable 104 d and the main body 102 d), the thickness of the tank housing 142 d decreases with increasing distance away from the mouthpiece 136 d. In particular, the tank housing 142 d tapers in this way, because internal and external surfaces of the tank housing 142 d are angled with respect to the first demolding direction. This tapering assists in forming the tank housing 142 d and passage wall 144 d as a single (i.e., unitary) component.

Like the tank housing 142 d, the passage wall 144 d is also tapered such that the thickness of the passage wall 144 d decreases along the first demolding direction. Again, the thickness of the passage wall 144 d decreases due to internal and external surfaces of the passage wall 144 d being angled with respect to the first demolding direction. As a result of the tapering of the passage wall 144 d, the passage 140 d has an internal diameter that decreases in a downstream direction (i.e., an upward direction in FIG. 17A). For example, the passage 140 d has an internal width less than 4.0 mm and greater than 3.0 mm at an upstream end of the passage 140 d (e.g., approximately 3.6 mm). On the other hand, the passage 140 d has an internal width of less than 3.8 mm and greater than 2.8 mm at the downstream end of the passage 140 d (e.g., approximately 3.4 mm).

The mouthpiece 136 d comprises a mouthpiece aperture 148 d defining an outlet of the passage 140 d. The mouthpiece aperture 148 d has a radially inwardly directed inner surface 150 d, which joins an outer surface 152 d of the mouthpiece 136 d (i.e., a surface which contacts a user's lips in use) at an outer edge 154 d of the mouthpiece aperture 148 d. At this outer edge 154 d, the included angle between the inner surface 150 d of the mouthpiece aperture 148 d and the outer surface 152 d of the mouthpiece 136 d (i.e., the “mouthpiece angle”) is greater than 90 degrees. In the illustrated embodiment, this is due to the outer edge 154 d being rounded. This outer edge 154 d may otherwise be chamfered or beveled.

The vaporizer 132 d is located in a vaporizing chamber 156 d of the consumable 104 d. This is best shown in FIG. 17B, which provides a detailed view of the vaporizing chamber 156 d. The vaporizing chamber 156 d is downstream of the air inlet 134 d of the consumable 104 d and is fluidly connected to the mouthpiece aperture 148 d (i.e., outlet) by the passage 140 d. In particular, the passage 140 d extends between the mouthpiece aperture 148 d and a passage opening 158 d from the vaporizing chamber 156 d. This passage opening 158 d is formed in a downstream (i.e., upper) wall 160 d of the vaporizing chamber 156 d.

The vaporizer 132 d comprises a porous wick 162 d and a heater filament 164 d coiled around the porous wick 162 d. As is apparent from FIG. 17A and FIG. 17B, the porous wick 162 d extends transversely across the vaporizing chamber 156 d between sidewalls 166 ad, 166 b of the vaporizing chamber 156 d which form part of an inner sleeve 168 d of a silicone insert 170 d that defines the lower end 111 d of the consumable 104 d that connects with the main body 102 d. The insert 170 d is inserted into an open lower end of the tank 106 d so as to seal against the internal surface of the tank housing 142 d.

In this way, the inner sleeve 168 d projects into the tank 106 d and seals with the passage 140 d (around the passage wall 144 d) so as to separate the vaporizing chamber 156 d from the e-liquid in the tank 106 d. Ends of the porous wick 162 d project through apertures in the inner sleeve 168 d and into the tank 106 d so as to be in contact with the e-liquid in the tank 106 d. In this way, e-liquid is transported along the porous wick 162 d (e.g., by capillary action) to a central portion of the porous wick 162 d. The transported e-liquid is heated by the heater filament 164 d (when activated, e.g., by detection of inhalation), which causes the e-liquid to be vaporized and to be entrained in air flowing in the vaporizing chamber 156 d. This vaporized liquid may cool to form an aerosol in the passage 140 d, which may then be inhaled by a user.

In some cases, un-vaporized liquid can be carried by air flowing through the vaporizing chamber 156 d. This may be undesirable for a user. To reduce or avoid this, the consumable 104 d comprises a baffle 172 d, which is shown in more detail in FIG. 17B. The baffle 172 d extends across the vaporizing chamber 156 d so as to be interposed between the vaporizer 132 d and the passage opening 158 d. In this way, un-vaporized liquid from the porous wick 162 d may collect on an upstream (i.e., lower) planar surface 174 d of the baffle 172 d rather than entering the passage opening 158 d. The baffle 172 d also causes the chamber airflow path from the vaporizer 132 d to the passage opening 158 d to be redirected around the baffle 172 d.

The baffle 172 d depends from and is integral with a (second) side wall 166 b of the vaporizing chamber 156 d, i.e., the baffle 172 d is integral with the silicone insert 170 d. The baffle 172 d comprises an upstream edge 176 d around which the airflow is redirected. This upstream edge 176 d and the (first) sidewall 166 a of the vaporizing chamber 156 d define a single aperture 178 d at a lateral edge of the baffle 172 d. The aperture 178 d is laterally offset from the longitudinal axis of the passage opening 158 d. The baffle 172 d further comprises a downstream edge 179 d.

As shown in FIG. 17C, first portion 182 d of the chamber airflow path extends in a generally longitudinal direction to the vaporizer 132 d from the air inlet 134 d and is aligned with the axial center of the device (i.e., aligned with the longitudinal axis of the passage 140 d). A second portion 183 d of the chamber airflow path then extends generally radially from the vaporizer 132 d to the aperture 178 d. Thus, there is a first lateral deflection in the chamber airflow path as it passes from the vaporizer 132 d to the aperture 178 d.

A third portion 184 d of the chamber airflow path from the aperture 178 d (i.e., the upstream edge 176 d of the baffle 179 d) to the downstream edge 179 d of the baffle 172 d is generally longitudinal and is laterally offset from the axial center of the device. Thus, there is a first axial deflection between the second and third portions 183 d, 184 d of the chamber air flow path. The transverse cross-sectional area of the third portion 184 d of the chamber air flow path as it passes between the upstream and downstream edges 176 d, 179 d is substantially constant.

A fourth portion 185 d of the chamber airflow path between the third portion 184 d and the passage 140 d extends generally radially (laterally) parallel to a planar upper surface of the baffle 172 d, such that there is a second lateral deflection between the third and fourth portions 184 d, 185 d of the chamber airflow path.

The chamber airflow path may then comprise a second axial deflection from the lateral direction (of the fourth portion) to a longitudinal direction as it leaves the vaporizing chamber 156 d at the passage opening 158 d.

Upon inhalation by a user at the mouthpiece aperture 148 d, air flows along the single, unified chamber airflow path around the porous wick 162 d, through the aperture 178 d and into the passage 140 d via the passage opening 158 d.

FIG. 18 shows a drawing of a manufacturing assembly 282 d which is used to manufacture the consumable 104 d. The manufacturing assembly 282 d comprises a first mold 284 d and a second mold 286 d.

The first mold 284 d has a shape which complements that of a first end of the integrally formed tank housing 142 d and mouthpiece 136 d. The first mold 284 d therefore has a shape which matches the inner surfaces defining the tank 106 d.

The second mold 286 d has a shape which complements that of a second end of the integrally formed tank housing 142 d and mouthpiece 136 d. The second mold 286 d has a shape which matches the outer surface of the mouthpiece 136 d and the inner surface of the mouthpiece aperture 148 d.

When the first mold 284 d and the second mold 286 d are brought together, they define a closed cavity which has the shape of the tank housing 142 d, the mouthpiece 136 d and the passage walls 144 d.

To manufacture these components, heated material is injected into the cavity between the first mold 284 d and the second mold 286 d. At this point, the first mold 284 d and the second mold 286 d meet at a boundary between external surfaces of the mouthpiece 136 d and the tank housing 142 d.

The material is subsequently cooled, and the first mold 284 d and the second mold 286 d are separated, with the first mold 284 d travelling in the first demolding direction 288 d (i.e., away from the second mold 286 d) and the second mold 286 d travelling in a second demolding direction 290 d (i.e., away from the first mold 284 d and opposite to the first demolding direction 288 d). For a particular component, a demolding direction is a direction along which a mold which contacts that component is removed during an injection molding process.

The insert 170 d and any additional components are subsequently inserted into the tank 106 d.

Fifth Mode: An Aerosol Delivery Device with an Airflow Path Circumventing a Vaporizer

Aspects and embodiments of the fifth mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

FIG. 19A shows a first embodiment of a smoking substitute system 100 e. In this example, the smoking substitute system 100 e includes a main body 102 e and an aerosol delivery device in the form of a consumable 104 e. The consumable 104 e may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e., open systems), the main body may be integral with the consumable such that the aerosol delivery device incorporates the main body. In such systems, a tank of the aerosol delivery device may be accessible for refilling the device.

In this example, the smoking substitute system 100 e is a closed system vaping system, wherein the consumable 104 e includes a sealed tank 106 e and is intended for single-use only. The consumable 104 e is removably engageable with the main body 102 e (i.e., for removal and replacement). FIG. 19A shows the smoking substitute system 100 e with the main body 102 e physically coupled to the consumable 104 e, FIG. 19B shows the main body 102 e of the smoking substitute system 100 e without the consumable 104 e, and FIG. 19C shows the consumable 104 e of the smoking substitute system 100 e without the main body 102 e.

The main body 102 e and the consumable 104 e are configured to be physically coupled together by pushing the consumable 104 e into a cavity at an upper end 108 e of the main body 102 e, such that there is an interference fit between the main body 102 e and the consumable 104 e. In other examples, the main body 102 e and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.

The consumable 104 e includes a mouthpiece (not shown in FIG. 19A, 18 or 1C) at an upper end 109 e of the consumable 104 e, and one or more air inlets (not shown) in fluid communication with the mouthpiece such that air can be drawn into and through the consumable 104 e when a user inhales through the mouthpiece. The tank 106 e containing e-liquid is located at the lower end 111 e of the consumable 104 e.

The tank 106 e includes a window 112 e, which allows the amount of e-liquid in the tank 106 e to be visually assessed. The main body 102 e includes a slot 114 e so that the window 112 e of the consumable 104 e can be seen whilst the rest of the tank 106 e is obscured from view when the consumable 104 e is inserted into the cavity at the upper end 108 e of the main body 102 e.

The lower end 111 e of the main body 102 e also includes a light 116 e (e.g., an LED) located behind a small translucent cover. The light 116 e may be configured to illuminate when the smoking substitute system 100 e is activated. While not shown, the consumable 104 e may identify itself to the main body 102 e, via an electrical interface, RFID chip, or barcode.

FIG. 20A and FIG. 20B are schematic drawings of the main body 102 e and consumable 104 e. As is apparent from FIG. 20A, the main body 102 e includes a power source 118 e, a controller 120 e, a memory 122 e, a wireless interface 124 e, an electrical interface 126 e, and, optionally, one or more additional components 128 e.

The power source 118 e is preferably a battery, more preferably a rechargeable battery. The controller 120 e may include a microprocessor, for example. The memory 122 e preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120 e to perform certain tasks or steps of a method.

The wireless interface 124 e is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 124 e could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 124 e may also be configured to communicate wirelessly with a remote server.

The electrical interface 126 e may be located in a base of the aperture in the upper end 108 e of the main body 102 e. When the main body 102 e is physically coupled to the consumable 104 e, the electrical interface 126 e is configured to transfer electrical power from the power source 118 e to the consumable 104 e (i.e., upon activation of the smoking substitute system 100 e).

The electrical interface 126 e may be configured to receive power from a charging station when the main body 102 e is not physically coupled to the consumable 104 e and is instead coupled to the charging station. The electrical interface 126 e may also be used to identify the consumable 104 e from a list of known consumables. For example, the consumable 104 e may be a particular flavor and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126 e). This can be indicated to the controller 120 e of the main body 102 e when the consumable 104 e is connected to the main body 102 e. Additionally, or alternatively, there may be a separate communication interface provided in the main body 102 e and a corresponding communication interface in the consumable 104 e such that, when connected, the consumable 104 e can identify itself to the main body 102 e.

The additional components 128 e of the main body 102 e may comprise the light 116 e discussed above.

The additional components 128 e of the main body 102 e may also comprise a charging port (e.g., USB or micro-USB port) configured to receive power from the charging station (i.e., when the power source 118 e is a rechargeable battery). This may be located at the lower end 110 e of the main body 102 e. Alternatively, the electrical interface 126 e discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

The additional components 128 e of the main body 102 e may, if the power source 118 e is a rechargeable battery, include a battery charging control circuit, for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in the charging station (if present).

The additional components 128 e of the main body 102 e may include a sensor, such as an airflow (i.e., puff) sensor for detecting airflow in the smoking substitute system 100 e, e.g., caused by a user inhaling through a mouthpiece 136 e of the consumable 104 e. The smoking substitute system 100 e may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable 104 e. The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece or how many times a user draws on the mouthpiece in a particular time period.

The additional components 128 e of the main body 102 e may include a user input, e.g., a button. The smoking substitute system 100 e may be configured to be activated when a user interacts with the user input (e.g., presses the button). This provides an alternative to the airflow sensor as a mechanism for activating the smoking substitute system 100 e.

As shown in FIG. 20B, the consumable 104 e includes the tank 106 e, an electrical interface 130 e, a vaporizer 132 e, one or more air inlets 134 e, a mouthpiece 136 e, and one or more additional components 138 e.

The electrical interface 126 e of the main body 102 e and an electrical interface 130 e of the consumable 104 e are configured to contact each other and thereby electrically couple the main body 102 e to the consumable 104 e when the lower end 110 e of the consumable 104 e is inserted into the upper end of the main body 102 e (as shown in FIG. 19A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118 e in the main body 102 e to the vaporizer 132 e in the consumable 104 e.

The vaporizer 132 e is configured to heat and vaporize e-liquid contained in the tank 106 e using electrical energy supplied from the power source 118 e. As will be described further below, the vaporizer 132 e includes a heating filament and a wick. The wick draws e-liquid from the tank 106 e and the heating filament heats the e-liquid to vaporize the e-liquid.

The one or more air inlets 134 e are preferably configured to allow air to be drawn into the smoking substitute system 100 e, when a user inhales through the mouthpiece 136 e. When the consumable 104 e is physically coupled to the main body 102 e, the air inlets 134 e receive air, which flows to the air inlets 134 e along a gap between the main body 102 e and the lower end 110 e of the consumable 104 e.

In operation, a user activates the smoking substitute system 100 e, e.g., through interaction with a user input forming part of the main body 102 e or by inhaling through the mouthpiece 136 e as described above. Upon activation, the controller 120 e may supply electrical energy from the power source 118 e to the vaporizer 132 e (via electrical interfaces 126 e, 130 e), which may cause the vaporizer 132 e to heat e-liquid drawn from the tank 106 e to produce a vapor which is inhaled by a user through the mouthpiece 136 e.

An example of one of the one or more additional components 138 e of the consumable 104 e is an interface for obtaining an identifier of the consumable 104 e. As discussed above, this interface may be, for example, an RFID reader, a barcode, a QR code reader, or an electronic interface which is able to identify the consumable. The consumable 104 e may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electronic interface in the main body 102 e.

It should be appreciated that the smoking substitute system 100 e shown in FIG. 19A to FIG. 20B is just one exemplary implementation of a smoking substitute system. For example, the system could otherwise be in the form of an entirely disposable (single-use) system or an open system in which the tank is refillable (rather than replaceable).

FIG. 21 is a section view of the consumable 104 e described above. The consumable 104 e comprises a tank 106 e for storing e-liquid, a mouthpiece 136 e and a passage 140 e extending along a longitudinal axis of the consumable 104 e. In the illustrated embodiment the passage 140 e is in the form of a tube having a substantially circular transverse cross-section (i.e., transverse to the longitudinal axis). The tank 106 e surrounds the passage 140 e, such that the passage 140 e extends centrally through the tank 106 e.

A tank housing 142 e of the tank 106 e defines an outer casing of the consumable 104 e, whilst a passage wall 144 e defines the passage 140 e. The tank housing 142 e extends from the lower end 111 e of the consumable 104 e to the mouthpiece 136 e at the upper end 109 e of the consumable 104 e. At the junction between the mouthpiece 136 e and the tank housing 142 e, the mouthpiece 136 e is wider than the tank housing 142 e, so as to define a lip 146 e that overhangs the tank housing 142 e. This lip 146 e acts as a stop feature when the consumable 104 e is inserted into the main body 102 e (i.e., by contact with an upper edge of the main body 102 e).

The tank 106 e, the passage 140 e and the mouthpiece 136 e are integrally formed with each other so as to form a single unitary component. This component may be formed by way of an injection molding process and, for example, may be formed of a thermoplastic material such as polypropylene.

Although not immediately apparent from the figures, the tank housing 142 e tapers, such that the thickness of the tank housing 142 e decreases in a downward direction away from the mouthpiece 136 e. This means that, aside from a small number of indents (which provide physical connection between the consumable 104 e and the main body 102 e), the thickness of the tank housing 142 e decreases with increasing distance away from the mouthpiece 136 e. In particular, the tank housing 142 e tapers in this way, because internal and external surfaces of the tank housing 142 e are angled with respect to the downward direction away from the mouthpiece 136 e. This tapering assists in forming the tank housing 142 e and passage wall 144 e as a single (i.e., unitary) component.

The mouthpiece 136 e comprises a mouthpiece aperture 148 e defining an outlet of the passage 140 e.

The vaporizer 132 e is located in a vaporizing chamber 156 e of the consumable 104 e. The vaporizing chamber 156 e is downstream of the air inlets 134 e (discussed later with references to FIG. 22A-FIG. 22C) of the consumable 104 e and is fluidly connected to the mouthpiece aperture 148 e (i.e., outlet) by the passage 140 e. In particular, the passage 140 e extends between the mouthpiece aperture 148 e and an opening 158 e from the chamber 156 e. This opening 158 e is formed in a downstream (i.e., upper) wall 160 e of the chamber 156 e.

The lower end 111 e (i.e., base) of the consumable 104 e that connects with the main body 102 e is defined by a base insert 170 e. The base insert 170 e is inserted into an open lower end of the tank 106 e so as to seal against an internal surface of the tank housing 142 e.

The vaporizer 132 e comprises a porous wick 162 e and a heater filament 164 e (not shown in FIG. 21, but described in more detail below in relation to FIG. 22A to FIG. 22C) coiled around the porous wick 162 e. The porous wick 162 e extends transversely across the chamber 156 e between sidewalls of the chamber 156 e which form part of an inner sleeve 168 e of the base insert 170 e.

The inner sleeve 168 e projects into the tank 106 e and seals with the passage 140 e (around the passage wall 144 e) so as to separate the chamber 156 e from the e-liquid in the tank 106 e. Transverse ends of the porous wick 162 e project into the tank 106 e so as to be in contact with the e-liquid in the tank 106 e. In this way, e-liquid is transported along the porous wick 162 e (e.g., by capillary action) to a central portion of the porous wick 162 e that is exposed to airflow through the chamber 156 e. The transported e-liquid is heated by the heater filament 164 e (when activated, e.g., by detection of inhalation), which causes the e-liquid to be vaporized and to be entrained in air flowing within the vaporizing chamber 156 e. This vaporized liquid may cool to form an aerosol in the passage 140 e, which may then be inhaled by a user.

FIG. 22A illustrates the base insert 170 e of the consumable 104 e. FIG. 22A also illustrates the coiled heater filament 164 e but does not show the porous wick 162 e. A pair of contact pins 200 e having a circular cross section in the longitudinal direction are embedded in the base portion 170 e. As is more clearly shown in FIG. 22C, the contact pins 200 e extend through the base portion 170 e in a direction substantially parallel to the longitudinal axis of the consumable 104 e.

An upper (downstream) face 202 e of each of the pair of contact pins 200 e is electrically connected to respective ends of the heater filament 164 e. The upper face 202 e of each of the pair of contact pins 200 e is also physically connected to respective ends of the heater filament 164 e. The upper faces 202 e of the contact pins 200 e may be connected to the heater filament 164 e by crimping, welding or compressing.

As shown in FIG. 22B, a lower (upstream) face 204 e of each of the contact pins 200 e comprises the electrical interface 130 e for interfacing with the corresponding electrical interface 126 e on the main body 102 e. Thus, when the consumable 104 e is engaged with the main body 102 e, the lower faces 204 e of the contact pins 200 e contact corresponding electrical contacts on the main body 102 e. As the main body electrical contacts are electrically connected to the power source 118 e, power can be supplied by the main body 102 e, via the contact pins 200 e, to the heater filament 164 e in order to heat the heater filament 164 e.

The contact pins 200 e are aligned with each other in a transverse direction perpendicular to the longitudinal direction of the device. The contact pins 200 e are also transversely aligned parallel to the transversely extending porous wick 162 e.

Furthermore, as shown more clearly in FIG. 22C, the connection between the upper face 202 e of each contact pin 200 e and the heater filament 164 e is located upstream of the heater filament 164 e and porous wick 162 e.

As shown in FIG. 22C, the heater filament 164 e and the porous wick 162 e are positioned to overlie the axial center of the base insert 170 e. Accordingly, the heater filament 164 e and porous wick 162 e are centrally positioned in the consumable 104 e in the transverse plane relative to the longitudinal axis of the consumable 104 e, such that the central longitudinal axis 210 e of the consumable 104 e intersects the heater filament 164 e and porous wick 162 e.

Each contact pin 200 e is spaced in the transverse direction from the central longitudinal axis 210 e of the consumable 104 e. Specifically, each contact pin 200 e is spaced from the central longitudinal axis 210 e of the consumable 104 e by a same distance on either side of the central longitudinal axis 210 e.

Each of the contact pins 200 e is substantially cylindrical. However, as shown in FIG. 22A-FIG. 22C, each contact pin 200 e tapers towards the upper face 202 e, which is connected to the heater filament 164 e.

The contact pins 200 e may be formed from a metal/metal alloy with high electrical conductivity. The contact pins 200 e may be formed from one or more of silver, copper, gold, platinum, palladium, tungsten, nickel, graphite, molybdenum, for example.

As previously mentioned, the heater filament 164 e and porous wick 162 e are positioned within a vaporizing chamber 156 e. As shown in FIG. 22A-FIG. 22C, a pair of inlet channels 220 e extend through the base insert 170 e into the vaporizing chamber 156 e. The inlet channels extend in a generally longitudinal direction of the device. They allow air to flow through the base insert 170 e from air inlets 134 e at the lowermost surface 111 e of the consumable 104 e (i.e., lowermost surface of the base portion 170 e), through openings 224 e into the vaporizing chamber 156 e. Thus, by drawing on the mouthpiece 136 e, a user may draw air through the air inlets 134 e, the inlet channels 220 e, the vaporizing chamber 156 e, the passage 140 e, and out through the outlet defined by the mouthpiece aperture 148 e in the mouthpiece 136 e.

In FIG. 22A-FIG. 22C, the two openings 224 e of the inlet channels 220 e are transversely offset from the central longitudinal axis 210 e of the consumable 104 e on either side of the central longitudinal axis 210 e in the front to back direction. The two openings 224 e of the inlet channels 220 e are equally spaced from the central longitudinal axis 210 e of the aerosol delivery device on either side of the central longitudinal axis 210 e. They are aligned with each other in the front to rear direction.

The openings 224 e of the inlet channels 220 e are formed in perpendicular stepped portions 230 e in the front and rear walls of the vaporizing chamber 156 e. The stepped portions 230 e in the front and rear walls, and therefore the openings 224 e of the inlet channels 220 e, are axially downstream of the heater filament 164 e and the porous wick 162 e.

The openings 224 e of the inlet channels 220 e are elongated in the transverse direction such that they extend substantially parallel to the transversely-extending porous wick 162 e. The air inlets 134 e at the lowermost surface 111 e of the base portion 170 e are also elongated in the transverse direction such that they extend substantially parallel to the transverse axis aligning the lower faces 204 e of the contact pins 200 e on the lowermost surface of the base portion.

Sixth Mode: A Smoking Substitute Device Having an Air Inlet

Aspects and embodiments of the sixth mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

FIG. 23A shows a first embodiment of a smoking substitute system 100 f. In this example, the smoking substitute system 100 f includes a device 102 f and a consumable 104 f. The consumable 104 f may alternatively be referred to as a “pod”, “cartridge” or “cartomizer”. It should be appreciated that in other examples (i.e., open systems), the device may be integral with the consumable. In such (open) systems, a tank of the aerosol delivery device may be accessible for refilling the device.

In this example, the smoking substitute system 100 f is a closed system vaping system, wherein the consumable 104 f includes a sealed tank 106 f and is intended for single-use only. The consumable 104 f is removably engageable with the device 102 f (i.e., for removal and replacement). FIG. 23A shows the smoking substitute system 100 f with the device 102 f physically coupled to the consumable 104 f, FIG. 23B shows the device 102 f of the smoking substitute system 100 f without the consumable 104 f, and FIG. 23C shows the consumable 104 f of the smoking substitute system 100 f without the device 102 f.

The device 102 f and the consumable 104 f are configured to be physically coupled together by pushing the consumable 104 f into a cavity (not shown in FIG. 23A-FIG. 23C) at an upper end 108 f of the device 102 f, such that there is an interference fit between the device 102 f and the consumable 104 f. In other examples, the device 102 f and the consumable may be coupled by screwing one onto the other, or through a bayonet fitting.

The consumable 104 f includes a mouthpiece (not shown in FIG. 23A-1C) at an upper end 109 f of the consumable 104 f, and one or more air inlets (again, not shown) in fluid communication with the mouthpiece such that air can be drawn into and through the consumable 104 f when a user inhales through the mouthpiece. The tank 106 f containing e-liquid is located at the lower end 111 f of the consumable 104 f.

The tank 106 f includes a window 112 f, which allows the amount of e-liquid in the tank 106 f to be visually assessed. The device 102 f includes a slot 114 f so that the window 112 f of the consumable 104 f can be seen whilst the rest of the tank 106 f is obscured from view when the consumable 104 f is inserted into the cavity at the upper end 108 f of the device 102 f.

The lower end 110 f of the device 102 f also includes a light 116 f (e.g., an LED) located behind a small translucent cover. The light 116 f may be configured to illuminate when the smoking substitute system 100 f is activated. Whilst not shown, the consumable 104 f may identify itself to the device 102 f, via an electrical interface, RFID chip, or barcode.

FIG. 24A and FIG. 24B are schematic drawings of the device 102 f and consumable 104 f. As is apparent from FIG. 24A, the device 102 f includes a power source 118 f, a controller 120 f, a memory 122 f, a wireless interface 124 f, an electrical interface 126 f, and, optionally, one or more additional components 128 f.

The power source 118 f is preferably a battery, more preferably a rechargeable battery. The controller 120 f may include a microprocessor, for example. The memory 122 f preferably includes non-volatile memory. The memory may include instructions which, when implemented, cause the controller 120 f to perform certain tasks or steps of a method.

The wireless interface 124 f is preferably configured to communicate wirelessly with another device, for example a mobile device, e.g., via Bluetooth®. To this end, the wireless interface 124 f could include a Bluetooth® antenna. Other wireless communication interfaces, e.g., Wi-Fi®, are also possible. The wireless interface 124 f may also be configured to communicate wirelessly with a remote server.

The electrical interface 126 f of the device 102 f may include one or more electrical contacts. The electrical interface 126 f may be located at a base of the cavity in the upper end 108 f of the device 102 f. When the device 102 f is physically coupled to the consumable 104 f, the electrical interface 126 f is configured to transfer electrical power from the power source 118 f to the consumable 104 f (i.e., upon activation of the smoking substitute system 100 f).

The electrical interface 126 f may be configured to receive power from a charging station when the device 102 f is not physically coupled to the consumable 104 f and is instead coupled to the charging station. The electrical interface 126 f may also be used to identify the consumable 104 f from a list of known consumables. For example, the consumable 104 f may be a particular flavor and/or have a certain concentration of nicotine (which may be identified by the electrical interface 126 f). This can be indicated to the controller 120 f of the device 102 f when the consumable 104 f is connected to the device 102 f. Additionally, or alternatively, there may be a separate communication interface provided in the device 102 f and a corresponding communication interface in the consumable 104 f such that, when connected, the consumable 104 f can identify itself to the device 102 f.

The additional components 128 f of the device 102 f may comprise the light 116 f discussed above.

The additional components 128 f of the device 102 f may also comprise a charging port (e.g., USB or micro-USB port) configured to receive power from the charging station (i.e., when the power source 118 f is a rechargeable battery). This may be located at the lower end 110 f of the device 102 f. Alternatively, the electrical interface 126 f discussed above may be configured to act as a charging port configured to receive power from the charging station such that a separate charging port is not required.

The additional components 128 f of the device 102 f may, if the power source 118 f is a rechargeable battery, include a battery charging control circuit, for controlling the charging of the rechargeable battery. However, a battery charging control circuit could equally be located in the charging station (if present).

The additional components 128 f of the device 102 f may include a sensor, such as an airflow (i.e., puff) sensor for detecting airflow in the substitute system 100 f, e.g., caused by a user inhaling through a mouthpiece 136 f of the consumable 104 f. The smoking substitute system 100 f may be configured to be activated when airflow is detected by the airflow sensor. This sensor could alternatively be included in the consumable 104 f. The airflow sensor can be used to determine, for example, how heavily a user draws on the mouthpiece or how many times a user draws on the mouthpiece in a particular time period.

The additional components 128 f of the device 102 f may include a user input, e.g., a button. The smoking substitute system 100 f may be configured to be activated when a user interacts with the user input (e.g., presses the button). This provides an alternative to the airflow sensor as a mechanism for activating the smoking substitute system 100 f.

As shown in FIG. 24B, the consumable 104 f includes the tank 106 f, an electrical interface 130 f, a vaporizer 132 f, one or more air inlets 134 f, a mouthpiece 136 f, and one or more additional components 138 f.

The electrical interface 130 f of the consumable 104 f may include one or more electrical contacts. The electrical interface 126 f of the device 102 f and an electrical interface 130 f of the consumable 104 f are configured to contact each other and thereby electrically couple the device 102 f to the consumable 104 f when the lower end 111 f of the consumable 104 f is inserted into the cavity at the upper end of the device 102 f (as shown in FIG. 23A). In this way, electrical energy (e.g., in the form of an electrical current) is able to be supplied from the power source 118 f of the device 102 f to the vaporizer 132 f of the consumable 104 f.

The vaporizer 132 f is configured to heat and vaporize e-liquid contained in the tank 106 f using electrical energy supplied from the power source 118 f. As will be described further below, the vaporizer 132 f includes a heating filament and a wick. The wick draws e-liquid from the tank 106 f and the heating filament heats the e-liquid to vaporize the e-liquid.

The one or more air inlet(s) 134 f are preferably configured to allow air to be drawn into the consumable 104 f, when a user inhales through the mouthpiece 136 f. As will be discussed further below, when the consumable 104 f is physically coupled to the device 102 f air flows along an airflow path between the device 102 f and the lower end 111 f of the consumable 104 f to the air inlet(s) of the consumable 104 f.

In operation, a user activates the smoking substitute system 100 f, e.g., through interaction with a user input forming part of the device 102 f or by inhaling through the mouthpiece 136 f as described above. Upon activation, the controller 120 f may supply electrical energy from the power source 118 f to the vaporizer 132 f (via electrical interfaces 126 f, 130 f), which may cause the vaporizer 132 f to heat e-liquid drawn from the tank 106 f to produce a vapor which is inhaled by a user through the mouthpiece 136 f.

An example of one of the one or more additional components 138 f of the consumable 104 f is an interface for obtaining an identifier of the consumable 104 f. As discussed above, this interface may be, for example, an RFID reader, a barcode, a QR code reader, or an electronic interface which is able to identify the consumable. The consumable 104 f may, therefore include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the electronic interface in the device 102 f.

It should be appreciated that the smoking substitute system 100 f shown in FIG. 23A to FIG. 24B is just one exemplary implementation of a smoking substitute system. For example, the system could otherwise be in the form of an entirely disposable (single-use) system or an open system in which the tank is refillable (rather than replaceable).

FIG. 25A is a schematic section view of an upper end of the device 102 f. The device 102 f comprises a body 174 f accommodating the power source 118 f, and side walls 176 f. The side walls 176 f extend (upwardly) from an end surface 184 f of the body 174 f in a longitudinal direction so as to define a cavity 178 f for receipt of the consumable 104 f. In order to facilitate engagement with the consumable 104 f, two of the side walls 176 f include two inwardly extending projections 180 f. These projections 180 f engage with recesses of the consumable 104 f when received in the cavity 178 f, so as to help retain the consumable 104 f in the cavity 178 f. When engaged in this manner (as shown in FIG. 25B), the consumable 104 f interfaces with the electrical interface 130 f (in the form of electrical contacts) of the device 102 f such that power is supplied to the consumable 104 f from the power source 118 f of the device 102 f.

Each of the side walls 176 f comprises an air inlet aperture 182 f formed therein. Each air inlet aperture 182 f is formed in its respective side wall 176 f at a (longitudinal) position that is adjacent the end surface 184 f of the cavity 178 f. That is, a lower edge of each aperture 182 f is aligned with the end surface 184 f of the cavity 178 f. As will be discussed further below with response to FIG. 25B, this positioning of the apertures 182 f allows air (i.e., that is external to the device 102 f) to be directed into the cavity 178 f in a substantially transverse direction and between body 174 f (i.e., the end surface 184 f) and the consumable 104 f.

FIG. 25B is a section view of the device 102 f engaged with the consumable 104 f. The consumable 104 f comprises a tank 106 f for storing e-liquid, a mouthpiece 136 f and a passage 140 f extending along a longitudinal axis of the consumable 104 f. In the illustrated embodiment the passage 140 f is in the form of a tube having a substantially circular transverse cross-section (i.e., transverse to the longitudinal axis). The tank 106 f surrounds the passage 140 f, such that the passage 140 f extends centrally through the tank 106 f.

A tank housing 142 f of the tank 106 f defines an outer casing of the consumable 104 f, whilst a passage wall 144 f defines the passage 140 f. The tank housing 142 f extends from the lower end 111 f of the consumable 104 f to the mouthpiece 136 f at the upper end 109 f of the consumable 104 f. At the junction between the mouthpiece 136 f and the tank housing 142 f, the mouthpiece 136 f is wider than the tank housing 142 f, so as to define a lip 146 f that overhangs the tank housing 142 f. This lip 146 f acts as a stop feature when the consumable 104 f is inserted into the device 102 f (i.e., by contact with an upper end of the side walls 176 f of the device 102 f).

The tank 106 f, the passage 140 f and the mouthpiece 136 f are integrally formed with each other so as to form a single unitary component. As will be described further below with respect to FIG. 26, this component may be formed by way of an injection molding process and, for example, may be formed of a thermoplastic material such as polypropylene.

Although not immediately apparent from the figures, the tank housing 142 f tapers, such that the thickness of the tank housing 142 f decreases in a first demolding direction (as will be discussed further with respect to FIG. 26). In FIG. 25A the first demolding direction is in a downward direction away from the mouthpiece 136 f. This means that, aside from a small number of indents (which provide physical connection between the consumable 104 f and the device 102 f), the thickness of the tank housing 142 f decreases with increasing distance away from the mouthpiece 136 f. In particular, the tank housing 142 f tapers in this way, because internal and external surfaces of the tank housing 142 f are angled with respect to the first demolding direction. This tapering assists in forming the tank housing 142 f and passage wall 144 f as a single (i.e., unitary) component.

Like the tank housing 142 f, the passage wall 144 f is also tapered such that the thickness of the passage wall 144 f decreases along the first demolding direction. Again, the thickness of the passage wall 144 f decreases due to internal and external surfaces of the passage wall 144 f being angled with respect to the first demolding direction. As a result of the tapering of the passage wall 144 f, the passage 140 f has an internal diameter that decreases in a downstream direction (i.e., an upward direction in FIG. 25B). For example, the passage 140 f has an internal width less than 4.0 mm and greater than 3.0 mm at an upstream end of the passage 140 f (e.g., approximately 3.6 mm). On the other hand, the passage 140 f has an internal width of less than 3.8 mm and greater than 2.8 mm at the downstream end of the passage 140 f (e.g., approximately 3.4 mm).

The mouthpiece 136 f comprises a mouthpiece aperture 148 f defining an outlet of the passage 140 f. The mouthpiece aperture 148 f has a radially inwardly directed inner surface 150 f, which joins an outer surface 152 f of the mouthpiece 136 f (i.e., a surface which contacts a user's lips in use) at an outer edge 154 f of the mouthpiece aperture 148 f. At this outer edge 154 f, the included angle between the inner surface 150 f of the mouthpiece aperture 148 f and the outer surface 152 f of the mouthpiece 136 f (i.e., the “mouthpiece angle”) is greater than 90 degrees. In the illustrated embodiment, this is due to the outer edge 154 f being rounded. This outer edge 154 f may otherwise be chamfered or beveled.

The vaporizer 132 f is located in a vaporizing chamber 156 f of the consumable 104 f. The vaporizing chamber 156 f is fluidly connected to the mouthpiece aperture 148 f (i.e., outlet) by the passage 140 f. In particular, the passage 140 f extends between the mouthpiece aperture 148 f and a passage opening 158 f from the chamber 156 f. This passage opening 158 f is formed in a downstream (i.e., upper) wall 160 f of the chamber 156 f.

The air inlet 134 f of the consumable 104 f (as discussed above) is an air inlet 134 f to the vaporizing chamber. This air inlet 134 f is fluidly connected to each of the air inlet apertures 182 f via respective airflow paths that extend transversely across the end surface 184 f of the body 174 f. In particular, these airflow paths are defined between the body 174 f (i.e., the end surface 184 f) and the consumable 104 f (i.e., the insert 170 f). That is, when the consumable 104 f is received in the cavity 178 f, a gap is maintained between the insert 170 f and the end surface 184 f. This gap is aligned with the air inlet apertures 182 f to permit transverse airflow therethrough. Whilst not shown, the end surface 184 f or the consumable 104 f may comprise guide surfaces (e.g., ribs) that project therefrom so as to at least partly define the airflow path (e.g., to define the transverse path that the airflow takes).

The vaporizer 132 f comprises a porous wick 162 f and a heater filament 164 f coiled around the porous wick 162 f. The porous wick 162 f extends transversely across the chamber 156 f between sidewalls 166 f of the chamber 156 f which form part of an inner sleeve 168 f of an insert 170 f that defines the lower end 111 f of the consumable 104 f (i.e., that connects with the device 102 f). The insert 170 f is inserted into an open lower end of the tank 106 f so as to seal against the tank housing 142 f.

In this way, the inner sleeve 168 f projects into the tank 106 f and seals with the passage 140 f (around the passage wall 144 f) so as to separate the chamber 156 f from the e-liquid in the tank 106 f. Ends of the porous wick 162 f project through apertures in the inner sleeve 168 f and into the tank 106 f so as to be in contact with the e-liquid in the tank 106 f. In this way, e-liquid is transported along the porous wick 162 f (e.g., by capillary action) to a central portion of the porous wick 162 f that is exposed to airflow through the chamber 156 f. The transported e-liquid is heated by the heater filament 164 f (when activated, e.g., by detection of inhalation), which causes the e-liquid to be vaporized and to be entrained in air flowing past the porous wick 162 f. This vaporized liquid may cool to form an aerosol in the passage 140 f, which may then be inhaled by a user.

In some cases, un-vaporized liquid can be carried by air flowing through the chamber 156 f. This may be undesirable for a user. To reduce this, the consumable 104 f comprises a baffle 172 f. The baffle 172 f extends across the chamber 156 f so as to be interposed between the vaporizer 132 f and the passage opening 158 f. In this way, un-vaporized liquid from the porous wick 162 f may collect on an upstream (i.e., lower) planar surface of the baffle 172 f rather than entering the passage opening 158 f.

FIG. 26 shows a drawing of a manufacturing assembly 286 f which is used to manufacture the consumable 104 f described above. The manufacturing assembly 286 f comprises a first mold 288 f and a second mold 290 f.

The first mold 288 f has a shape which complements that of a first end of the integrally formed tank housing 142 f and mouthpiece 136 f. The first mold 288 f therefore has a shape which matches the inner surfaces defining the tank 106 f.

The second mold 290 f has a shape which complements that of a second end of the integrally formed tank housing 142 f and mouthpiece 136 f. The second mold 290 f has a shape which matches the outer surface of the mouthpiece 136 f and the inner surface of the mouthpiece aperture 148 f.

When the first mold 288 f and the second mold 290 f are brought together, they define a closed cavity which has the shape of the tank housing 142 f, the mouthpiece 136 f and the passage walls 144 f.

To manufacture these components, heated material is injected into the cavity between the first mold 288 f and the second mold 290 f. At this point, the first mold 288 f and the second mold 290 f meet at a boundary between external surfaces of the mouthpiece 136 f and the tank housing 142 f.

The material is subsequently cooled, and the first mold 288 f and the second mold 290 f are separated, with the first mold 288 f travelling in a first demolding direction 292 f (i.e., away from the second mold 290 f) and the second mold 290 f travelling in a second demolding direction 294 f (i.e., away from the first mold 288 f and opposite to the first demolding direction 292 f). For a particular component, a demolding direction is a direction along which a mold which contacts that component is removed during an injection molding process.

Subsequently, the insert 170 f (e.g., including the vaporizer) and any additional components are inserted into the tank 106 f to form the consumable 104 f.

CONCLUSION

The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilized for realizing the disclosure in diverse forms thereof.

While the disclosure has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the disclosure set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the disclosure.

For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

Throughout this specification, including the claims which follow, unless the context requires otherwise, the words “have”, “comprise”, and “include”, and variations such as “having”, “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means, for example, +/−10%.

The words “preferred” and “preferably” are used herein refer to embodiments of the disclosure that may provide certain benefits under some circumstances. It is to be appreciated, however, that other embodiments may also be preferred under the same or different circumstances. The recitation of one or more preferred embodiments therefore does not mean or imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure, or from the scope of the claims. 

1. An aerosol delivery device comprising: a flow passage configured to provide fluid communication between a vaporizer and a mouthpiece aperture, so that the mouthpiece aperture receives a flow comprising an aerosol vapor formed from liquid vaporized by the vaporizer in use; and a turbulence inducing element, the turbulence inducing element located in the flow passage and configured to turn the flow towards a circumferential direction of the aerosol delivery device.
 2. An aerosol delivery device according to claim 1 further comprising the vaporizer.
 3. An aerosol delivery device according to claim 2, wherein the aerosol delivery device comprises a vaporizer chamber containing the vaporizer, and wherein the turbulence inducing element is at least partially located in the vaporizer chamber.
 4. An aerosol delivery device according to claim 1, wherein the turbulence inducing element is located at least 1 mm downstream of the vaporizer.
 5. An aerosol delivery device comprising: a vaporizer configured to form an aerosol vapor from e-liquid; a flow passage configured to provide fluid communication between the vaporizer and a mouthpiece aperture, so that the mouthpiece aperture receives a flow comprising the aerosol vapor in use; a turbulence inducing element, the turbulence inducing element located in the flow passage and configured to induce turbulence in the flow; and a vaporizer chamber containing the vaporizer and the turbulence inducing element, wherein the turbulence inducing element is at least 1 mm downstream of the vaporizer.
 6. An aerosol delivery device according to claim 5, wherein the turbulence inducing element is at least partially located within the vaporizer chamber.
 7. An aerosol delivery device according to claim 4, wherein the turbulence inducing element is at least 2 mm downstream of the vaporizer.
 8. An aerosol delivery device according to claim 7, wherein the turbulence inducing element is at least 2.5 mm downstream of the vaporizer.
 9. An aerosol delivery device according to claim 4, wherein the turbulence inducing element is at most 5 mm downstream of the vaporizer.
 10. An aerosol delivery device according to claim 9, wherein the turbulence inducing element is at most 4 mm downstream of the vaporizer.
 11. An aerosol delivery device according to claim 4, wherein the turbulence inducing element is substantially 3 mm downstream of the vaporizer.
 12. An aerosol delivery device according to claim 5, wherein the turbulence inducing element is configured to turn the flow towards a circumferential direction.
 13. An aerosol delivery device according to claim 5, wherein the turbulence inducing element is further configured to turn the flow towards a radial direction of the aerosol delivery device.
 14. An aerosol delivery device according to claim 13, wherein the turbulence inducing element comprises a baffle across the flow passage, the baffle forming a first flow obstacle to turn the flow towards the radial direction.
 15. An aerosol delivery device according to claim 14, wherein the baffle is configured to effect branching of the flow.
 16. An aerosol delivery device according to claim 5, wherein the turbulence inducing element comprises an upstand, and the flow passage comprises an outlet tube, wherein the outlet tube and the upstand are configured to together form a second flow obstacle to turn the flow towards the circumferential direction.
 17. An aerosol delivery device according to claim 16, wherein the second flow obstacle is configured to effect additional branching of the flow.
 18. An aerosol delivery device according to claim 5, wherein the turbulence inducing element comprises an outlet, the turbulence inducing element further configured to turn the flow such that the flow is in a substantially axial direction at the outlet.
 19. An aerosol delivery device according to claim 18, wherein the turbulence inducing element comprises a protrusion forming a third flow obstacle to turn the flow towards the axial direction.
 20. An aerosol delivery device according claim 5, further comprising a reservoir for storing a liquid, the reservoir in fluid communication with the vaporizer to pass liquid to the vaporizer for vaporization. 21.-92. (canceled) 